Yamaha TDM850 Owner`s manual

OWNER’S MANUAL
TDM850
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2000 · 9 - 0.4 × 1 CR
(E)
4TX-28199-E5
H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
INTRODUCTION
EAU03338
Welcome to the Yamaha world of motorcycling!
As the owner of a TDM850, you are benefiting from Yamaha’s vast experience and
newest technology regarding 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 TDM850. 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!
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
WARNING
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
@
@
EAU00005
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IMPORTANT MANUAL INFORMATION
EW000002
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
@
@
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
IMPORTANT MANUAL INFORMATION
EAU03337
TDM850
OWNER’S MANUAL
© 2000 by Yamaha Motor Co., Ltd.
1st Edition, August 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
TABLE OF CONTENTS
EAU00009
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY ................................................ 1-1
1
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
GIVE SAFETY THE RIGHT OF WAY
EAU00021
1-
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
1-1
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DESCRIPTION
Left view ............................................................................................. 2-1
Right view........................................................................................... 2-2
Controls and instruments ................................................................... 2-3
2
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DESCRIPTION
EAU00026
2-
Left view
2
1. Coolant reservoir
2. Helmet holder
3. Seat lock
4. Shock absorber assembly spring preload
adjusting nut (fine adjustment)
5. Shock absorber assembly damping force
adjusting dial
(page 6-12)
(page 3-11)
(page 3-11)
(page 3-15)
(page 3-16)
2-1
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DESCRIPTION
Right view
2
6. Luggage strap holders
7. Shock absorber assembly spring preload
adjusting lever (coarse adjustment)
8. Fuses
9. Engine oil level check window
10. Front fork spring preload adjusting bolt
11. Front fork damping force adjusting screw
(page 3-17)
(page 3-15)
(page 6-35)
(page 6-9)
(page 3-13)
(page 3-14)
2-2
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DESCRIPTION
Controls and instruments
2
1. Clutch lever
2. Left handlebar switches
3. Starter (choke) lever
4. Speedometer unit
5. Main switch/steering lock
6. Tachometer
7. Fuel gauge
8. Right handlebar switches
9. Throttle grip
10. Brake lever
(page 3-7)
(page 3-5)
(page 3-10)
(page 3-3)
(page 3-1)
2-3
(page 3-4)
(page 3-5)
(page 3-6)
(page 6-19)
(page 3-7)
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INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .....................................3-1
Indicator and warning lights ................................3-2
Speedometer unit ................................................3-3
Tachometer ..........................................................3-4
Self-diagnosis device ..........................................3-4
Anti-theft alarm (optional) ....................................3-5
Fuel gauge ...........................................................3-5
Handlebar switches .............................................3-5
Clutch lever ..........................................................3-7
Shift pedal ............................................................3-7
Brake lever ..........................................................3-7
Brake pedal ..........................................................3-8
Fuel tank cap .......................................................3-9
Fuel ..................................................................... 3-9
Fuel tank breather hose (for Germany only) ..... 3-10
Starter (choke) lever .......................................... 3-10
Seat ................................................................... 3-11
Helmet holder .................................................... 3-11
Storage compartment ....................................... 3-12
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assembly ............ 3-15
Luggage strap holders ...................................... 3-17
Sidestand .......................................................... 3-17
Ignition circuit cut-off system ............................. 3-18
3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00027
3-
3
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00036
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1
1. Push.
2. Turn.
EW000016
WARNING
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motorcycle is stopped before turning the
key to “OFF” or “LOCK”.
@
@
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU01590
EAU00063
(Parking)
The steering is locked, and the taillight
and auxiliary light are 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 “ ”.
High beam indicator light “
”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU01707
ECA00043
CAUTION:
Do not use the parking position for
an extended length of time, otherwise the battery may discharge.
_
_
1.
2.
3.
4.
5.
6.
Left turn signal indicator light “
”
Neutral indicator light “ ”
High beam indicator light “
”
Coolant temperature warning light “
Right turn signal indicator light “
”
Fuel level warning light “ ”
”
EAU03034
Indicator and warning lights
EAU03299
Turn signal indicator lights
“
”/“
”
The corresponding indicator light flashes when the turn signal switch is
pushed to the left or right.
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 according to the following procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on while
pushing the start switch, have a
Yamaha dealer check the electrical circuit.
EC000002
EAU00061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
CAUTION:
Do not operate the engine if it is
overheated.
@
@
3-2
3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU03680
3
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
3.1 L. When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light
can be checked according to the following procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on, have a
Yamaha dealer check the electrical circuit.
1.
2.
3.
4.
Speedometer
Odometer/tripmeter/clock
“SELECT” button
“RESET” button
EAU03492
Speedometer unit
The speedometer unit is equipped with
the following:
● a speedometer (which shows the
riding speed)
● an odometer (which shows the total distance traveled)
● two tripmeters (which show the
distance traveled since they were
last set to zero)
● a clock
3-3
Odometer and tripmeter modes
Pushing the “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP 1”, “TRIP 2” and “CLOCK” in the
following order:
ODO→TRIP 1→TRIP 2→CLOCK→
ODO
To reset a tripmeter, select it by pushing the “SELECT” button, and then
push the “RESET” button for at least
one second. The tripmeters can be
used to estimate the distance that can
be traveled with a full tank of fuel. This
information will enable you to plan future fuel stops.
Clock mode
To change the display to the clock
mode, push both the “SELECT” and
“RESET” buttons.
To change the display back to the
odometer mode, push the “SELECT”
button.
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
To set the clock
1. Push both the “SELECT” and
“RESET” buttons for at least two
seconds.
2. When the hour digits start flashing,
push the “RESET” button to set
the hours.
3. Push the “SELECT” button to
change the minutes.
4. When the minute digits start flashing, push the “RESET” button to
set the minutes.
5. Push the “SELECT” button to start
the clock.
NOTE:
After setting the clock, be sure to push
the “SELECT” button before turning the
key to “OFF”, otherwise the clock will
not be set.
EAU00103
Self-diagnosis device
This model is equipped with a self-diagnosis device for the throttle position
sensor circuit.
If the throttle position sensor circuit is
defective, the tachometer will repeatedly display the following error code:
CB-10E
3,000 r/min
for 2.5 seconds
Current engine
speed for
3 seconds
EAU00101
Tachometer
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
@
@
0 r/min for
3 seconds
1. Tachometer
2. Tachometer red zone
EC000003
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 8,000 r/min and above
@
@
If the tachometer displays such an error code, have a Yamaha dealer check
the motorcycle.
EC000004
CAUTION:
When the tachometer displays an
error code, the motorcycle should
be checked as soon as possible in
order to avoid engine damage.
@
@
3-4
3
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00109
Anti-theft alarm (optional)
This motorcycle can be equipped with
an optional anti-theft alarm by a
Yamaha dealer. Contact a Yamaha
dealer for more information.
3
1. Fuel gauge
EAU00110
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 3.1 L 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.
@
@
3-5
1.
2.
3.
4.
5.
Pass switch “PASS”
Dimmer switch
Turn signal switch
Horn switch “
”
Hazard switch “
”
EAU00118
Handlebar switches
EAU00120
Pass switch “PASS”
Press this switch to flash the headlight.
EAU00121
Dimmer switch
Set this switch to “
” for the high
beam and to “
” for the low beam.
E_4tx.book Page 6 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00127
EAU00143
Turn signal switch
To signal a right-hand turn, push this
switch to “
”. To signal a left-hand
turn, push this switch to “
”. When
released, the switch returns to the center position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
Start switch “ ”
Push this switch to crank the engine
with the starter.
EAU00129
Horn switch “
”
Press this switch to sound the horn.
EC000005
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
@
@
1. Engine stop switch
2. Light switch
3. Start switch “
”
EAU00138
EAU03826
Hazard switch “
”
With the key in the “ON” or “ ” position, use this switch to turn on the hazard 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 motorcycle is stopped
where it might be a traffic hazard.
EC000006
CAUTION:
Do not use the hazard light for an extended length of time, otherwise the
battery may discharge.
Engine stop switch
Set this switch to “ ” to stop the engine in case of an emergency, such as
when the motorcycle overturns or
when the throttle cable is stuck.
EAU00134
Light switch
Set this switch to “
” to turn on the
auxiliary light, meter lighting and taillight. Set the switch to “
” to turn on
the headlight also.
_
_
3-6
3
E_4tx.book Page 7 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Clutch lever
1. Shift pedal
EAU00152
EAU00157
Clutch lever
Shift pedal
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition circuit cut-off system. (See
page 3-18 for an explanation of the ignition circuit cut-off system.)
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 5-speed constant-mesh transmission equipped on
this motorcycle.
3-7
1. Brake lever
2. Brake lever position adjusting nut
a. Distance between brake lever and handlebar
grip
EAU00160
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
E_4tx.book Page 8 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Brake lever position adjusting nut
2. Properly aligned marks
1. Brake pedal
The brake lever is equipped with a position adjusting nut. To adjust the distance between the brake lever and the
handlebar grip, turn the adjusting nut
while holding the lever pushed away
from the handlebar grip. Make sure that
the mark “ ” on the adjusting nut is
aligned with the mark “ ” on the brake
lever.
Brake pedal
EAU00162
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
3-8
E_4tx.book Page 9 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
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 unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
@
3
@
1. Fuel tank cap lock cover
2. Unlock.
EWA00025
EAU02935
Fuel tank cap
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
1. Fuel tank filler tube
2. Fuel level
@
@
To open the fuel tank cap
Open the fuel tank cap lock cover, insert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be
opened.
EAU03753
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
_
To close the fuel tank cap
1. Push the fuel tank cap into position with the key inserted in the
lock.
_
3-9
WARNING
● Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.
E_4tx.book Page 10 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00186
_
CAUTION:
● Immediately wipe off spilled fuel
with a clean, dry, soft cloth,
since fuel may deteriorate painted surfaces or plastic parts.
● For Germany only: Whenever
replacement is necessary, use a
fuel tank cap of the same special design as the original.
3
1. Fuel tank breather hose
1. Starter (choke) lever “
”
EAU00196
_
EAU00191
Recommended fuel:
Regular unleaded gasoline with a
research octane number of 91 or
higher
Fuel tank capacity:
Total amount:
20 L
Reserve amount:
3.1 L
Fuel tank breather hose
(for Germany only)
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.
NOTE:
If knocking (or pinging) occurs, use
gasoline of a different brand or with a
higher octane grade.
_
_
3-10
EAU02976*
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).
E_4tx.book Page 11 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Seat lock
2. Unlock.
EAU01726
Seat
To remove the seat
1. Insert the key into the seat lock,
and then turn it clockwise.
2. Pull the seat off.
1. Projection (× 2)
2. Seat holder (× 2)
1. Helmet holder
To install the seat
1. Insert the projections on the front
of the seat into the seat holders as
shown.
2. Push the rear of the seat down to
lock it in place.
3. Remove the key.
Helmet holder
EAU00263*
NOTE:
Make sure that the seat is properly secured before riding.
@
@
3-11
The helmet holder is located under the
seat.
To secure a helmet to the helmet
holder
1. Remove the seat.
2. Attach the helmet to the helmet
holder, and then securely install
the seat.
E_4tx.book Page 12 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EW000030
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
@
@
To release the helmet from the helmet holder
Remove the seat, remove the helmet
from the helmet holder, and then install
the seat.
3
1. U-LOCK (optional)
2. Strap
1. U-LOCK (optional)
2. Strap (× 2)
EAU01688
Storage compartment
This storage compartment is designed
to hold a genuine Yamaha U-LOCK.
(Other locks may not fit.) When placing
a U-LOCK in the storage compartment,
securely fasten it with the straps. When
the U-LOCK is not in the storage compartment, be sure to secure the straps
to prevent losing them.
3-12
When storing the owner’s manual or
other documents in the storage compartment, be sure to wrap them in a
plastic bag so that they will not get wet.
When washing the motorcycle, be
careful not to let any water enter the
storage compartment.
E_4tx.book Page 13 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU01728
CI-10E
Adjusting the front fork
The front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
EW000035
WARNING
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
@
3
@
1.
2.
3.
4.
Spring preload adjusting bolt
Current setting
Standard setting
Front fork cap bolt
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in direction a. To decrease the spring preload
and
thereby
soften
the
suspension, turn the adjusting bolt on
each fork leg in direction b.
NOTE:
Align the appropriate groove on the adjusting mechanism with the top of the
front fork cap bolt.
@
@
3-13
Setting
Minimum (soft)
1
Standard
3
Maximum (hard)
5
E_4tx.book Page 14 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EC000015
CAUTION:
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 specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
@
1. Damping force adjusting screw
Damping force
To increase the damping force and
thereby harden the damping, turn the
adjusting screw on each fork leg in direction a. To decrease the damping
force and thereby soften the damping,
turn the adjusting screw on each fork
leg in direction b.
@
CI-02E
Minimum (soft)
0 clicks in direction a*
Standard
1 click in direction a*
Maximum (hard)
4 clicks in direction a*
* With the adjusting screw fully turned in direction b
3-14
3
E_4tx.book Page 15 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
Spring preload
Coarse adjustment
For riding solo, move the adjusting lever (at the top of the shock absorber
assembly) to “SOFT”. For riding with a
passenger, move the adjusting lever to
“HARD”.
3
NOTE:
Use the special tool included in the
owner’s tool kit to make the adjustment.
_
1. Spring preload adjusting lever
EAU03834
Adjusting the shock absorber
assembly
_
This shock absorber assembly is
equipped with a spring preload adjusting lever and adjusting nut and a damping force adjusting dial.
EC000015
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
_
_
3-15
1. Locknut
2. Spring preload adjusting nut
Fine adjustment
1. Loosen the locknut.
2. To increase the spring preload
and thereby harden the suspension, turn the adjusting nut (at the
bottom of the shock absorber assembly) in direction a. To decrease the spring preload and
thereby soften the suspension,
turn the adjusting nut in
direction b.
E_4tx.book Page 16 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
3. Tighten the locknut to the specified torque.
Tightening torque:
Locknut:
40 Nm (4.0 m·kg)
EC000018
CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
3
_
a. Distance A
NOTE:
The spring preload setting is determined by measuring distance A, shown
in the illustration. The shorter distance
A is, the lower the spring preload; the
longer distance A is, the higher the
spring preload.
_
_
1. Damping force adjusting dial
Damping force
To increase the damping force and
thereby harden the damping, turn the
adjusting dial in direction a. To decrease the damping force and thereby
soften the damping, turn the adjusting
dial in direction b.
CI-04E
_
Spring preload:
Minimum (soft):
Distance A = 59 mm
Standard:
Distance A = 61 mm
Maximum (hard):
Distance A = 63 mm
Minimum (soft)
20 clicks in direction b*
Standard
10 clicks in direction b*
Maximum (hard)
0 clicks in direction b*
* With the adjusting dial fully turned in direction a
3-16
E_4tx.book Page 17 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00315
WARNING
This shock absorber contains highly pressurized nitrogen gas. For
proper handling, read and understand the following information before handling the shock absorber.
The manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
EAU00330
Sidestand
@
3
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle 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.)
@
1. Luggage strap holder (× 4)
EAU00324
Luggage strap holders
There are four luggage strap holders
below the passenger seat, two of which
can be turned out for easier access.
@
3-17
@
E_4tx.book Page 18 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
EW000044
WARNING
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), otherwise the sidestand could contact
the ground and distract the operator, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the sidestand before starting off. Therefore,
check this system regularly as described below and have a Yamaha
dealer repair it if it does not function
properly.
@
@
EAU03720
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
● It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EW000045
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
_
_
3-18
3
E_4tx.book Page 19 Wednesday, October 4, 2000 4:28 PM
INSTRUMENT AND CONTROL FUNCTIONS
CD-01E
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
3
YES
NOTE:
This check is most reliable if performed with
a warmed-up engine.
”.
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
3-19
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
PRE-OPERATION CHECKS
EAU01114
4-
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM
Fuel
4
Engine oil
Coolant
Front brake
Rear brake
Clutch
Throttle grip
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
CHECKS
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Make sure that operation is smooth.
Lubricate throttle grip, housing and cables if necessary.
Check free play.
If necessary, have Yamaha dealer make adjustment.
4-1
PAGE
3-9–3-10
6-9
6-11–6-13
6-25–6-26
6-23–6-26
6-23
6-19
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
PRE-OPERATION CHECKS
ITEM
Control cables
Drive chain
Wheels and tires
Brake and shift pedals
Brake and clutch levers
Sidestand
Chassis fasteners
Instruments, lights, signals
and switches
Sidestand switch
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
CHECKS
Make sure that operation is smooth.
Lubricate if necessary.
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary.
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
Make sure that operation is smooth.
Lubricate pivot if necessary.
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
Check operation.
Correct if necessary.
Check operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.
PAGE
6-29
6-27
6-19–6-22
6-30
4
6-31
6-31
—
—
3-17
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
_
_
EWA00033
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_
_
4-2
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
Starting a cold engine ....................................................................... 5-1
Starting a warm engine ..................................................................... 5-2
Shifting .............................................................................................. 5-3
Recommended shift points (for Switzerland only) ............................. 5-3
Tips for reducing fuel consumption ................................................... 5-4
Engine break-in ................................................................................. 5-4
Parking .............................................................................................. 5-5
5
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU00372
5-
EAU00373
@
5
WARNING
● Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
● Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
● Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
EAU03827*
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
_
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-19.
● Never ride with the sidestand
down.
●
_
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
@
5-1
EC000035
CAUTION:
If the fuel level warning light comes
on, check the fuel level, and, if necessary, refuel as soon as possible.
_
_
2. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical circuit.
_
_
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-10 for starter (choke) operation.)
4. Start the engine by pushing the
start switch.
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
soon as possible, and then
check the warning light again. If
the warning light does not come
on when pushing the start
switch, or if it does not go off after starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
_
_
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
_
ECA00022
_
EAU01258
Starting a warm engine
CAUTION:
● The coolant temperature warning light and fuel level warning
light should come on when the
start switch is pushed, and they
should go off when the start
switch is released.
● If the coolant temperature warning light remains on after starting, immediately stop the
engine, and then have a
Yamaha dealer check the electrical circuit.
● If the fuel level warning light remains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel as
5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00045
CAUTION:
For maximum engine life, never accelerate 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.
_
_
5-2
5
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
EC000048
@
1. Shift pedal
N. Neutral position
EAU00423
5
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 illustration.
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
@
5-3
EAU02941
Recommended shift points
(for Switzerland only)
The recommended shift points during
acceleration are shown in the table below.
CF-01E
Shift point
(km/h)
1st
2nd
3rd
4th
→
→
→
→
2nd
3rd
4th
5th
23
36
50
60
NOTE:
When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear).
_
_
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU00424
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
● Thoroughly warm up the engine.
● Turn the starter (choke) off as
soon as possible.
● Shift up swiftly, and avoid high engine 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 letting it idle for an extended length
of time (e.g., in traffic jams, at traffic lights or at railroad crossings).
EAU00436
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the engine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle operation or any condition that might result
in engine overheating must be avoided.
EAU00440*
0–150 km
● Avoid prolonged operation above
5,000 r/min.
● After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
● Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km
● Avoid prolonged operation above
6,000 r/min.
● Rev the engine freely through the
gears, but do not use full throttle at
any time.
500–1,000 km
● Avoid prolonged full-throttle operation.
● Avoid prolonged operation above
7,000 r/min.
5-4
5
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM
OPERATION AND IMPORTANT RIDING POINTS
EC000052*
CAUTION:
After 1,000 km of operation, the engine oil must be changed and the oil
filter element replaced.
@
EAU00460
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
@
1,000 km and beyond
The vehicle can now be operated normally.
@
EC000053
@
5
CAUTION:
● Keep the engine speed out of
the tachometer red zone.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●
@
@
5-5
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1
Periodic maintenance and lubrication chart .........6-2
Removing and installing cowlings and panels .....6-5
Checking the spark plugs ....................................6-7
Engine oil and oil filter element ............................6-9
Coolant ..............................................................6-11
Cleaning the air filter element ............................6-15
Adjusting the carburetors ...................................6-18
Adjusting the engine idling speed ......................6-18
Adjusting the throttle cable free play ..................6-19
Adjusting the valve clearance ............................6-19
Tires ...................................................................6-19
Adjusting the clutch lever free play ....................6-23
Adjusting the brake pedal position .....................6-23
Adjusting the rear brake light switch ..................6-24
Checking the front and rear brake pads .............6-25
Checking the brake fluid level ............................6-25
Changing the brake fluid ....................................6-26
Drive chain slack ................................................6-27
Lubricating the drive chain .................................6-29
Checking and lubricating the cables ..................6-29
Checking and lubricating the throttle grip and
cable ............................................................... 6-30
Checking and lubricating the brake and
shift pedals ...................................................... 6-30
Checking and lubricating the brake and
clutch levers .................................................... 6-31
Checking and lubricating the sidestand ............ 6-31
Lubricating the rear suspension ........................ 6-32
Checking the front fork ...................................... 6-32
Checking the steering ....................................... 6-33
Checking the wheel bearings ............................ 6-33
Battery ............................................................... 6-34
Replacing the fuses .......................................... 6-35
Replacing a headlight bulb ................................ 6-36
Replacing the tail/brake light bulb ..................... 6-37
Replacing a turn signal light bulb ...................... 6-38
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-39
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
6
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00462
6-
EAU00464
6
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of inspection, 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 general guide under normal riding conditions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
EW000060
WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
@
@
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
@
@
EW000063
WARNING
Modifications not approved by
Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha
dealer before attempting any changes.
@
1. Owner’s tool kit
EAU01299
Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-11 for seat removal
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
6-1
@
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03685
Periodic maintenance and lubrication chart
NOTE:
● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
● From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
_
_
CP-03E
NO.
ITEM
CHECK OR MAINTENANCE JOB
1
* Fuel line
• Check fuel hoses for cracks or damage.
2
* Fuel filter
• Check condition.
3
Spark plugs
ODOMETER READING (× 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
• Check condition.
• Clean and regap.
√
5
6
7
* Valves
Air filter element
Clutch
* Front brake
• Check valve clearance.
• Adjust.
* Rear brake
6
√
Every 40,000 km
√
• Clean.
√
√
• Replace.
√
• Check operation.
• Adjust.
√
√
√
√
√
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
√
√
√
√
√
• Replace brake pads.
8
√
√
• Replace.
4
√
√
Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Replace brake pads.
√
√
√
√
√
Whenever worn to the limit
6-2
√
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1,000 km)
1
10
√
• Check for cracks or damage.
20
30
40
ANNUAL
CHECK
√
√
√
√
9
* Brake hose
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.
√
√
√
√
14
Drive chain
6
15
* Steering bearings
16
* Chassis fasteners
17
Sidestand
• Replace. (See NOTE on page 6-4.)
Every 4 years
• Lubricate with molybdenum disulfide grease.
Every 50,000 km
• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.
• Check bearing play and steering for roughness.
Every 1,000 km and after washing
the motorcycle or riding in the rain.
√
√
• Lubricate with lithium-soap-based grease.
√
√
√
Every 20,000 km
• Make sure that all nuts, bolts and screws are properly tightened.
√
√
√
√
√
• Check operation.
• Lubricate.
√
√
√
√
√
√
√
√
√
√
18
* Sidestand switch
• Check operation.
19
* Front fork
√
• Check operation and for oil leakage.
√
√
√
√
Rear shock absorber
assembly
• Check operation and shock absorber for oil leakage.
√
√
√
√
Rear suspension relay
• Check operation.
√
√
√
√
20
*
21
* arm and connecting arm • Lubricate with molybdenum disulfide grease.
pivoting points
6-3
√
√
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NO.
22
ITEM
* Carburetors
CHECK OR MAINTENANCE JOB
• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.
ODOMETER READING (× 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
√
23
Engine oil
• Change.
√
24
Engine oil filter element • Replace.
√
25
* Cooling system
26
* switches
27
28
Front and rear brake
√
• Check coolant level and vehicle for coolant leakage.
• Change.
Lights, signals and
√
√
√
√
√
Every 3 years
√
• Check operation.
Moving parts and cables • Lubricate.
* switches
√
• Check operation.
• Adjust headlight beam.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
EAU03541
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
_
_
6-4
6
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Cowling A
2. Panel A
1. Cowling B
2. Panel B
1. Screw (× 3)
EAU03494
Cowlings A and B
To remove one of the cowlings
Remove the cowling screws, and then
pull the cowling off as shown.
EAU01139
Removing and installing
cowlings and panels
6
The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be removed and installed.
To install the cowling
Place the cowling in the original position, and then install the screws.
6-5
E_4tx.book Page 6 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw
EAU03317
Panels A and B
To remove one of the panels
1. Remove the corresponding cowling A or B. (See page 6-5 for cowling removal and installation
procedures.)
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove the screw, and then take
the panel off.
To install the panel
1. Place the panel in the original position, and then install the screw.
2. Install the seat and the cowling.
6
6-6
E_4tx.book Page 7 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
@
@
1. Spark plug cap
1. Spark plug wrench
EAU01668
Checking the spark plugs
6
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
To remove a spark plug
1. Remove cowling A. (See page 6-5
for cowling removal and installation procedures.)
2. Remove the spark plug cap.
3. Remove the spark plug as shown
with the spark plug wrench included 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-tolight tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
6-7
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
E_4tx.book Page 8 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
@
a. Spark plug gap
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
@
4. Install the spark plug cap.
5. Install the cowling.
6
Spark plug gap:
0.8–0.9 mm
2. Clean the surface of the spark
plug gasket and its mating surface, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
6-8
E_4tx.book Page 9 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01692
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter element replaced at the intervals specified
in the periodic maintenance and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
3. Check the oil level through the
check window located on the right
side of the engine oil tank.
6
NOTE:
Make sure that the motorcycle 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
15 minutes, and then turn it off.
NOTE:
● The engine oil tank is located behind the cylinders.
● The engine oil should be between
the minimum and maximum level
marks.
@
@
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-9
1. Engine oil tank cap
To change the engine oil (with or
without oil filter element replacement)
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.
E_4tx.book Page 10 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Engine oil drain bolt A
3. Remove the engine oil tank cap
and drain bolts to drain the oil from
the crankcase.
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (× 5)
1. Oil filter element
2. O-ring (× 2)
5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tightening them to the specified torque.
4. Remove the oil filter element cover
by removing the bolts.
NOTE:
Skip steps 4–6 if the oil filter element is
not being replaced.
@
@
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kg)
NOTE:
Make sure that the O-rings are properly
seated.
@
@
7. Install the engine oil drain bolts,
and then tighten them to the specified torques.
6-10
6
E_4tx.book Page 11 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000072
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kg)
Engine oil drain bolt B:
30 Nm (3.0 m·kg)
@
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil tank
cap.
6
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.5 L
With oil filter element
replacement:
3.6 L
Total amount (dry engine):
4.2 L
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
● Make sure that no foreign material 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,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03495
Coolant
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
If the engine overheats, see page 6-45
for further instructions.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
@
@
6-11
E_4tx.book Page 12 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000080
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
@
@
1. Coolant reservoir cap
3. If the coolant is at or below the
minimum level mark, remove the
seat (See page 3-11 for seat removal and installation procedures.), and then open the coolant
reservoir cap.
4. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then install the seat.
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling system will not be protected
against frost and corrosion.
● If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
EW000067
Coolant reservoir capacity:
0.3 L
6-12
WARNING
Never attempt to remove the radiator cap when the engine is hot.
6
E_4tx.book Page 13 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see page
6-45 for further instructions.
@
@
EAU03300
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowling and panel removal and installation procedures.)
4. Place a container under the engine to collect the used coolant.
1. Radiator cap retaining bolt
2. Radiator cap
5. Remove the radiator cap retaining
bolt and the radiator cap.
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
6
@
@
6-13
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PERIODIC MAINTENANCE AND MINOR REPAIR
12. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
13. Install the coolant drain bolts, and
then tighten them to the specified
torque.
NOTE:
Check the washers for damage and replace them if necessary.
@
1. Coolant drain bolt (× 2)
6. Remove the coolant drain bolts to
drain the cooling system.
1.
2.
3.
4.
Coolant reservoir
Bolt (× 2)
Clamp
Hose
@
7. Remove the coolant reservoir
bolts.
8. Slightly move the coolant reservoir
back, and then disconnect the
hose at the bottom of the coolant
reservoir.
9. Drain the coolant from the coolant
reservoir by opening the cap, then
turning the reservoir upside down.
10. Connect the hose to the coolant
reservoir.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolts.
6-14
Tightening torque:
Coolant drain bolt:
7 Nm (0.7 m·kg)
6
14. Pour the recommended coolant
into the radiator until it is full.
E_4tx.book Page 15 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.7 L
Coolant reservoir capacity:
0.3 L
EC000080
6
@
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling system will not be protected
against frost and corrosion.
●
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
@
15. Install the radiator cap, start the
engine, let it idle for several minutes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radiator, and then install the radiator
cap and the cap retaining bolt.
17. Check the coolant level in the reservoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Install the panel, the cowling, and
the seat.
19. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
6-15
1. Bolt (× 3)
EAU03496
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove cowlings A and B as well
as panels A and B. (See pages 6-5
and 6-6 for cowling and panel removal and installation procedures.)
3. Remove the fuel tank bolts.
E_4tx.book Page 16 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Fuel sender coupler
4. Disconnect the fuel sender coupler.
1. Fuel cock
2. Fuel hose
3. Fuel tank breather hose
5. Slightly lift the rear of the fuel tank,
turn the fuel cock lever to “OFF”,
disconnect the fuel hose and
breather hose, and then take the
fuel tank off.
6-16
1. Air filter case cover
2. Screw (× 3)
6. Remove the air filter case cover by
removing the screws.
6
E_4tx.book Page 17 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000082
@
1. Air filter element
7. Pull the air filter element out.
6
8. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
9. Insert the air filter element into the
air filter case.
CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
@
10. Install the air filter case cover by
installing the screws.
11. Connect the fuel hose, breather
hose and fuel sender coupler, turn
the fuel cock lever to “ON”, and
then install the fuel tank by installing the bolts.
EWA00013
WARNING
Make sure that the fuel hose and
breather hose are properly connected and routed, and not pinched. Replace any damaged hoses.
@
@
12. Install the panels and cowlings.
13. Install the seat.
6-17
E_4tx.book Page 18 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00630
Adjusting the carburetors
The carburetors are important parts of
the engine and require very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EAU00632
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.
1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally revving it to 4,000–5,000 r/min.
1. Throttle stop screw
2. Check the engine idling speed
and, if necessary, adjust it to specification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in direction a. To decrease the engine
idling speed, turn the screw in direction b.
EC000095
CAUTION:
The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowledge may result in poor performance of or damage to the engine.
@
NOTE:
The engine is warm when it quickly responds to the throttle.
@
@
Engine idling speed:
1,050–1,250 r/min
@
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
@
@
6-18
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00637
Tires
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
a. Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
6
EAU00658
Adjusting the valve clearance
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
_
The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
_
6-19
WARNING
● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
E_4tx.book Page 20 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
CE-01E
EWA00012
Tire air pressure
(measured on cold tires)
Load*
Front
_
Rear
Up to 90 kg
225 kPa
275 kPa
(2.25 kg/cm2, (2.75 kg/cm2,
2.25 bar)
2.75 bar)
90 kg–maximum
225 kPa
275 kPa
(2.25 kg/cm2, (2.75 kg/cm2,
2.25 bar)
2.75 bar)
High-speed riding
225 kPa
275 kPa
(2.25 kg/cm2, (2.75 kg/cm2,
2.25 bar)
2.75 bar)
CE-07E
Maximum load*
WARNING
Because loading has an enormous
impact on the handling, braking, performance and safety characteristics
of your motorcycle, you should keep
the following precautions in mind.
OVERLOAD
THE
● NEVER
MOTORCYCLE! Operation of an
overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure
that the total weight of rider, passenger, cargo, and accessories
does not exceed the specified
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.
203 kg
* Total weight of rider, passenger, cargo and
accessories
_
6-20
1. Tire sidewall
a. Tire tread depth
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
replace the tire immediately.
CE-08E
Minimum tire tread depth
(front and rear)
1.6 mm
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
_
_
6
E_4tx.book Page 21 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
_
6
EW000079
EW000080
WARNING
● Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding stability and can lead to loss of
control.
● The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
WARNING
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the motorcycle cannot be guaranteed.
After extensive tests, only the
tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
_
●
●
1. Tire air valve
2. Valve core
3. Valve cap with seal
●
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
●
_
_
6-21
E_4tx.book Page 22 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
CE-10E
FRONT
EAU00684
Manufacturer
Size
Model
Bridgestone
110/80 ZR18 (58W)
BT54F
Pirelli
110/80 ZR18 (58W)
MTR03
Michelin
110/80 ZR18 (58W) MACADAM 90X
WARNING
This motorcycle is fitted with superhigh-speed tires. Note the following
points in order to make the most efficient use of these tires.
● Use only the specified replacement tires. Other tires may run
the danger of bursting at super
high speeds.
● Brand-new tires can have a relatively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km
after installing a new tire.
● The tires must be warmed up
before a high-speed run.
● Always adjust the tire air pressure according to the operating
conditions.
@
REAR
Manufacturer
Size
Model
Bridgestone
150/70 ZR17 (69W)
BT54R
Pirelli
150/70 ZR17 (69W)
MTR04
Michelin
150/70 ZR17 (69W) MACADAM 90X
CE-14E
FRONT & REAR
Tire air valve
TR412
Valve core
#9000A (original)
@
6-22
6
E_4tx.book Page 23 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If the specified free play cannot be obtained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.
@
@
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
a. Distance between brake pedal and footrest
EAU00712
Adjusting the brake pedal
position
EAU00692
6
Adjusting the clutch lever free
play
The top of the brake pedal should be
positioned approximately 29 mm below
the top of the footrest as shown. Periodically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
The clutch lever free play should measure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch lever.
2. 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.
3. Tighten the locknut.
6-23
E_4tx.book Page 24 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000109
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
@
@
1. Brake light switch
2. Brake light switch adjusting nut
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is activated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.
6-24
6
E_4tx.book Page 25 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Front brake
Rear brake
1. Brake pad wear indicator (× 2)
1. Brake pad wear indicator (× 2)
EAU00715
Checking the front and rear
brake pads
6
Front brake
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake.
To check the brake pad wear, check
the position of the wear indicator while
applying the brake. If a brake pad has
worn to the point that the wear indicator
almost touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set.
6-25
1. Minimum level mark
EAU03776
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing 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 level is low, be sure to check the
brake pads for wear and the brake system for leakage.
E_4tx.book Page 26 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Rear brake
1. Minimum level mark
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
● Be careful that water does not enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
●
Recommended brake fluid: DOT 4
6-26
EAU03238
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrication chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.
● Oil seals: Replace every two
years.
● Brake hose: Replace every four
years.
6
E_4tx.book Page 27 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00744
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
@
6
@
a. Drive chain slack
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain
slack as shown.
Drive chain slack:
40–50 mm
4. If the drive chain slack is incorrect,
adjust it as follows.
6-27
1.
2.
3.
4.
Axle nut
Locknut
Drive chain slack adjusting nut
Alignment marks
EAU00765
To adjust the drive chain slack
1. Loosen the axle nut and the brake
caliper bracket bolt.
2. Loosen the chain puller locknut at
each end of the swingarm.
3. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction a. To loosen the drive chain, turn the adjusting nut at each end of the
swingarm in direction b, and then
push the rear wheel forward.
E_4tx.book Page 28 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
4. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
Tightening torques:
Axle nut:
110 Nm (11.0 m·kg)
Brake caliper bracket bolt:
35 Nm (3.5 m·kg)
1. Bolt
2. Brake caliper bracket
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same position for proper wheel alignment.
@
6
@
EC000096
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
@
@
6-28
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PERIODIC MAINTENANCE AND MINOR REPAIR
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
EAU03006
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
ECA00052
CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
@
EAU02962
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 cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
@
@
6
Recommended lubricant:
Engine oil
EW000112
@
1. Clean the drive chain with kerosene and a small soft brush.
WARNING
Damage to the outer sheath may interfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
@
ECA00053
CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam
cleaners,
high-pressure
washers or inappropriate solvents.
@
@
@
6-29
E_4tx.book Page 30 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03209
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.
Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
NOTE:
Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should always be lubricated at the same time.
@
EAU03370
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
@
1. Remove the throttle grip by removing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throttle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-30
6
E_4tx.book Page 31 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU03164
6
EAU03165
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EW000113
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
@
@
6-31
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
EAU00790
Lubricating the rear
suspension
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
@
Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Molybdenum disulfide grease
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
@
@
6-32
6
E_4tx.book Page 33 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
Checking the wheel bearings
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
6
EAU01144
Checking the steering
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
@
6-33
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00800
EW000116
Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:
Never attempt to remove the battery
cell seals, as this would permanently damage the battery.
@
@
@
WARNING
● Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
6-34
●
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
@
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with optional electrical accessories.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
6
E_4tx.book Page 35 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000102
@
6
@
CAUTION:
keep the battery
● Always
charged. Storing a discharged
battery can cause permanent
battery damage.
● To charge a sealed-type (MF)
battery, a special (constantvoltage) 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 charger, have a Yamaha
dealer charge your battery.
1.
2.
3.
4.
5.
6.
7.
Headlight fuse
Signaling system fuse
Ignition fuse
Hazard fuse
Odometer fuse
Radiator fan fuse
Spare fuse (× 4)
1. Main fuse
2. Spare main fuse
Specified fuses:
Main fuse:
Headlight fuse:
Signaling system fuse:
Ignition fuse:
Hazard fuse:
Odometer fuse:
Radiator fan fuse:
EAU03772
Replacing the fuses
The fuse boxes and main fuse box are
located under the seat. (See page 3-11
for seat removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
6-35
30 A
15 A
15 A
10 A
10 A
5A
7.5 A
EC000103
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_
_
E_4tx.book Page 36 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
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. Headlight bulb cover
EAU03794
1. Headlight coupler (× 2)
2. Headlight bulb holder
Replacing a headlight bulb
This motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Remove the headlight bulb cover,
and then disconnect the headlight
couplers.
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
_
3. Place a new bulb into position, and
then secure it with the bulb holder.
6-36
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Do not touch this area.
EC000105
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.
_
6
_
4. Connect the headlight couplers,
and then install the bulb cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Screw (× 2)
2. Tail/brake light lens
1. Tail/brake light bulb (× 2)
EC000108
EAU01623
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screws.
6-37
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
@
@
E_4tx.book Page 38 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw
2. Turn signal light lens
1. Turn signal light bulb
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
EAU03497
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 counterclockwise.
ECA00065
CAUTION:
Do not overtighten the screw, otherwise the lens may break.
@
@
6-38
6
E_4tx.book Page 39 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01579
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance requiring the motorcycle to
stand upright. Check that the motorcycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed under the engine for added stability.
6
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Wheel axle
2. Front wheel axle pinch bolt
EAU03498*
Front wheel
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To remove the front wheel
EW000122
@
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
●
@
1. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
2. Lift the front wheel off the ground
according to the procedure.
6-39
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PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake calipers onto the brake
discs.
_
_
5. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
1. Bolt (× 2)
2. Brake caliper
EAU03829
3. Remove the brake caliper on each
side by removing the bolts.
ECA00046
CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
@
@
4. Pull the wheel axle out, and then
remove the wheel.
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle from the
right-hand side.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by installing the bolts.
6-40
Tightening torques:
Wheel axle:
58 Nm (5.8 m·kg)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
6. Push down hard on the handlebar
several times to check for proper
fork operation.
6
E_4tx.book Page 41 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03830
Rear wheel
To remove the rear wheel
EW000122
_
_
6
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
1. Loosen the axle nut and the brake
caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-39.
1.
2.
3.
4.
Brake caliper
Bolt (× 2)
Bolt
Brake caliper bracket
3. Loosen the brake caliper bracket
bolt.
4. Remove the brake caliper by removing the bolts.
ECA00046
CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
_
_
6-41
E_4tx.book Page 42 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03501
1. Locknut
2. Drive chain slack adjusting nut
5. Loosen the locknut on each side of
the swingarm.
6. Turn the drive chain slack adjusting nuts 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. Remove the axle nut.
9. Pull the wheel axle out, and then
remove the wheel.
6-42
To install the rear wheel
1. Install the wheel by inserting the
wheel axle from the right-hand
side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-27 for
drive chain slack adjustment procedures.)
3. Install the brake caliper by installing the bolts.
4. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
5. Tighten the axle nut, the brake caliper bolts and the brake caliper
bracket bolt to the specified
torques.
Tightening torques:
Axle nut:
110 Nm (11.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
Brake caliper bracket bolt:
35 Nm (3.5 m·kg)
6
E_4tx.book Page 43 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03087
Troubleshooting
6
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
6-43
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02990
Troubleshooting charts
Starting problems or poor engine performance
EW000125
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
@
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
6
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-44
The engine does not start.
Have a Yamaha dealer
check the vehicle.
E_4tx.book Page 45 Wednesday, October 4, 2000 4:28 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
@
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
●
@
The coolant level is low.
Check the cooling system
for leakage.
Wait until the
engine has cooled.
6
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
@
@
6-45
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1
Storage .............................................................................................. 7-4
7
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
EAU03429
7-
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
7
Before cleaning
1. Cover the muffler outlets with plastic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
7-1
Cleaning
ECA00010
@
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
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 removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switches and lights), breather hoses
and vents.
●
●
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden part of the windshield to make sure that it does
not leave any marks. If the windshield is scratched, use a quality plastic polishing compound
after washing.
@
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.
@
@
7-2
7
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
@
@
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
7
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
7-3
EWA00001
@
@
WARNING
● Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
● Before operating the motorcycle test its braking performance and cornering behavior.
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
ECA00013
@
CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● 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.
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
@
@
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
@
@
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
@
7-4
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
7
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM
MOTORCYCLE CARE AND STORAGE
a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
7
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plastic bags to prevent moisture from
entering them.
EWA00003
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
@
@
7-5
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-34.
NOTE:
Make any necessary repairs before
storing the motorcycle.
@
@
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
Specifications .................................................................................... 8-1
Conversion table ............................................................................... 8-5
8
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
EAU01038
8-
Specifications
CS-01E
CS-01E
Model
TDM850
Engine oil
Type
Dimensions
Overall length
-20 -10
2,165 mm (for GB, NL, B, F, E, P,
I, GR, D, DK)
Overall height
Wheelbase
1,475 mm
Basic weight (with oil and full
fuel tank)
SAE 15W-40
1,285 mm
805 mm
Minimum turning radius
SAE 10W-40
790 mm
Seat height
Ground clearance
SAE 20W-40
SAE 20W-50
165 mm
Recommended engine oil
classification
2,900 mm
232 kg
Engine type
Liquid-cooled 4-stroke, DOHC
Cylinder arrangement
Forward-inclined parallel
2-cylinder
Displacement
849 cm3
Bore × stroke
89.5 × 67.5 mm
Compression ratio
10.5:1
Starting system
Electric starter
Lubrication system
Dry sump
API Service SE, SF, SG or
higher
CAUTION:
Engine
8
10 20 30 40 50 ˚C
SAE 10W-30
2,200 mm (for N, S, SF)
Overall width
0
Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.
Quantity
8-1
Without oil filter element
replacement
3.5 L
With oil filter element
replacement
3.6 L
Total amount (dry engine)
4.2 L
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
Cooling system capacity
(total amount)
1.7 L
Air filter
Dry type element
Operation
Gear ratio
Fuel
Type
Regular unleaded gasoline
Fuel tank capacity
20 L
Fuel reserve amount
3.1 L
Left foot
Carburetor
1st
2.643
2nd
1.947
3rd
1.500
4th
1.174
5th
0.964
Chassis
Manufacturer
MIKUNI
Frame type
Diamond
Model × quantity
BDSR38 × 2
Caster angle
24.5°
Trail
103 mm
Spark plug
Manufacturer/model
NGK / DPR8EA-9 or
DENSO / X24EPR-U9
Gap
0.8–0.9 mm
Clutch type
Tires
Front
Wet, multiple-disc
Transmission
Primary reduction system
1.718
Secondary reduction system
Chain drive
Secondary reduction ratio
2.688
Number of drive chain
sprocket teeth (front/rear)
Transmission type
Tubeless tire
Size
110/80 ZR18 (58W)
Manufacturer/model
Spur gear
Primary reduction ratio
Type
Bridgestone / BT54F
Pirelli / MTR03
Michelin / MACADAM90X
Rear
Type
Tubeless tire
16/43
Size
150/70 ZR17 (69W)
Constant-mesh 5-speed
Manufacturer/model
Bridgestone / BT54R
Pirelli / MTR04
Michelin / MACADAM90X
8-2
8
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
Maximum load*
203 kg
Brakes
Tire air pressure
(measured on cold tires)
Front
Type
Up to 90 kg*
Front
225 kPa (2.25 kg/cm2, 2.25 bar)
Rear
275 kPa (2.75 kg/cm2, 2.75 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
Rear
275 kPa (2.75 kg/cm2, 2.75 bar)
High-speed riding
Right hand
Fluid
DOT 4
Type
Single disc brake
Operation
Right foot
Fluid
DOT 4
Suspension
Front
225 kPa (2.25 kg/cm2, 2.25 bar)
Rear
275 kPa (2.75 kg/cm2, 2.75 bar)
* Total weight of rider, passenger, cargo and accessories
Front
Type
Cast wheel
Size
18 × MT 3.00
Type
Cast wheel
Size
17 × MT 4.00
Front
Telescopic fork
Rear
Swingarm (monocross)
Spring/shock absorber
Wheels
8
Operation
Rear
90 kg–maximum*
Front
Dual disc brake
Front
Coil spring / oil damper
Rear
Coil spring / gas-oil damper
Wheel travel
Rear
8-3
Front
149 mm
Rear
144 mm
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
Electrical system
Ignition system
Fuses
T.C.I. (digital)
Charging system
Main fuse
30 A
Headlight fuse
15 A
Type
A.C. magneto
Signaling system fuse
15 A
Standard output
14 V, 24 A @ 5,000 r/min
Ignition fuse
10 A
Hazard fuse
10 A
Model
GT12B-4
Odometer fuse
12 V, 10 Ah
Radiator fan fuse
Battery
Voltage, capacity
Headlight type
5A
7.5 A
Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight
12 V, 55 W × 2
Auxiliary light
12 V, 5 W × 1
Tail/brake light
12 V, 5/21 W × 2
Turn signal light
12 V, 21 W × 4
Meter lighting
12 V, 2 W × 3
Neutral indicator light
14 V, 1.4 W × 1
High beam indicator light
14 V, 1.4 W × 1
Turn signal indicator light
14 V, 1.4 W × 2
Coolant temperature
warning light
14 V, 1.4 W × 1
Fuel level warning light
12 V, 2 W × 1
8
8-4
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM
SPECIFICATIONS
EAU01064
Conversion table
CS-02E
Conversion table
All specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL
unit data.
Example
METRIC
MULTIPLIER
METRIC TO IMPERIAL
Metric unit
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
8
8-5
Multiplier
Imperial unit
Torque
m·kg
m·kg
cm·kg
cm·kg
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/h
0.6214
mi/h
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume,
Capacity
cc (cm3)
cc (cm3)
L (liter)
L (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/mm
kg/cm2
Centigrade (°C)
55.997
14.2234
9/5 + 32
lb/in
psi (lb/in2)
Fahrenheit (°F)
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1
Key identification number .................................................................. 9-1
Vehicle identification number ............................................................. 9-1
Model label ........................................................................................ 9-2
9
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
CONSUMER INFORMATION
EAU01039
9-
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. Key identification number
1. KEY IDENTIFICATION NUMBER:
CA-02E
2. VEHICLE IDENTIFICATION
NUMBER:
EAU01043
EAU01041
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
CA-02E
9
1. Vehicle identification number
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.
@
3. MODEL LABEL INFORMATION:
CA-01E
@
9-1
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
CONSUMER INFORMATION
1. Model label
EAU01050
Model label
The model label is affixed to the frame
under the seat. (See page 3-11 for seat
removal and installation procedures.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
9
9-2
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM
INDEX
10-
A
D
I
Air filter element, cleaning ......................6-15
Anti-theft alarm ........................................3-5
Dimmer switch......................................... 3-5
Drive chain, lubricating .......................... 6-29
Drive chain slack ................................... 6-27
Adjusting .......................................... 6-27
Checking.......................................... 6-27
Identification numbers ..............................9-1
Idling speed, adjusting ...........................6-18
Ignition circuit cut-off system ..................3-18
Indicator and warning lights......................3-2
B
Battery ...................................................6-34
Brake and clutch levers, checking and
lubricating ............................................6-31
Brake and shift pedals, checking and
lubricating ............................................6-30
Brake fluid, changing .............................6-26
Brake fluid level, checking......................6-25
Brake lever...............................................3-7
Brake light switch (rear), adjusting .........6-24
Brake pads, checking.............................6-25
Brake pedal..............................................3-8
Brake pedal position, adjusting ..............6-23
C
Cables, checking and lubricating............6-29
Carburetors, adjusting............................6-18
Care.........................................................7-1
Clutch lever..............................................3-7
Clutch lever free play, adjusting .............6-23
Conversion table......................................8-5
Coolant ..................................................6-11
Changing..........................................6-13
Checking ..........................................6-11
Coolant temperature warning light............3-2
Cowlings and panels, removing and
installing ................................................6-5
E
Engine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-9
Engine stop switch................................... 3-6
F
Front fork, adjusting............................... 3-13
Front fork, checking ............................... 6-32
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-5
Fuel level warning light ............................ 3-3
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap........................................... 3-9
Fuses, replacing .................................... 6-35
H
Handlebar switches ................................. 3-5
Hazard switch.......................................... 3-6
Headlight bulb, replacing ....................... 6-36
Helmet holder ........................................ 3-11
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6
K
Key identification number .........................9-1
L
Light switch ..............................................3-6
Luggage strap holders ...........................3-17
M
Main switch/steering lock .........................3-1
Model label ..............................................9-2
N
Neutral indicator light ...............................3-2
P
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch..............................................3-5
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list............................4-1
S
Safety information ....................................1-1
Seat .......................................................3-11
Self-diagnosis device ...............................3-4
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM
INDEX
Shifting .................................................... 5-3
Shift pedal ............................................... 3-7
Shift points (for Switzerland only)............. 5-3
Shock absorber assembly, adjusting ..... 3-15
Sidestand .............................................. 3-17
Sidestand, checking and lubricating....... 6-31
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever .............................. 3-10
Starting a cold engine .............................. 5-1
Starting a warm engine............................ 5-2
Start switch.............................................. 3-6
Steering, checking ................................. 6-33
Storage.................................................... 7-4
Storage compartment ............................ 3-12
Supporting the motorcycle ..................... 6-39
Suspension (rear), lubricating ................ 6-32
T
Tachometer ............................................. 3-4
Tail/brake light bulb, replacing ............... 6-37
Throttle cable free play, adjusting .......... 6-19
Throttle grip and cable, checking and
lubricating............................................ 6-30
Tires ...................................................... 6-19
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-43
Troubleshooting charts .......................... 6-44
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-38
Turn signal switch.................................... 3-6
V
Valve clearance, adjusting .................... 6-19
Vehicle identification number................... 9-1
W
Wheel bearings, checking ..................... 6-33
Wheel (front) ......................................... 6-39
Installing .......................................... 6-40
Removing ........................................ 6-39
Wheel (rear) .......................................... 6-41
Installing .......................................... 6-42
Removing ........................................ 6-41
H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM
H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM
OWNER’S MANUAL
TDM850
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2000 · 9 - 0.4 × 1 CR
(E)
4TX-28199-E5