Owner's manual | Yamaha FZS1000SC Owner`s manual

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2003.06-0.8

×1 CR

(E)

LIT-11626-17-40

OWNER’S MANUAL

FZS1000S

FZS1000SC

5LV-28199-13

5LV13.book Page 1 Monday, June 9, 2003 5:08 PM

EAU10041


INTRODUCTION

EAU10080

Congratulations on your purchase of the Yamaha FZS1000/FZS1000C. This model is the result of

Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines.

It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.

The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.


IMPORTANT MANUAL INFORMATION

EAU10130

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

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

WARNING

CAUTION:

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.

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

NOTE:

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

NOTE:

●

●

This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10010

WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY

AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTOR-

CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES

AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS

AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY

THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.


IMPORTANT MANUAL INFORMATION

EAU10192

AFFIX DEALER

LABEL HERE

FZS1000S/FZS1000SC


©2003 by Yamaha Motor Corporation, U.S.A.

1st edition, June 2003

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.

P/N LIT-11626-17-40


TABLE OF CONTENTS

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

Location of important labels ............1-5

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

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

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

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

Sidestand ..................................... 3-15

Ignition circuit cut-off system ........ 3-16

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

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

INSTRUMENT AND CONTROL

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

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

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

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

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

Self-diagnosis devices ....................3-4

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

Handlebar switches ........................3-5

Clutch lever .....................................3-6

Shift pedal .......................................3-7

Brake lever .....................................3-7

Brake pedal ....................................3-7

Fuel tank cap ..................................3-8

Fuel .................................................3-8

Starter (choke) lever .......................3-9

Seat ..............................................3-10

Helmet holder ...............................3-10

Storage compartment ...................3-11

Adjusting the front fork ..................3-11

Adjusting the shock absorber assembly ...................................3-13

EXUP system ...............................3-15

OPERATION AND IMPORTANT

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

Starting and warming up a cold engine ......................................... 5-1

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

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

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

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

PERIODIC MAINTENANCE AND

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

PERIODIC MAINTENANCE ........... 6-1

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

Periodic maintenance chart for the emission control system ............. 6-3

General maintenance and lubrication chart .......................... 6-5

Removing and installing panels ..... 6-9

Checking the spark plugs ............. 6-10

Canister (for California only) ........ 6-11

Engine oil and oil filter cartridge ... 6-12

Coolant ......................................... 6-14

Cleaning the air filter element ...... 6-17

Adjusting the carburetors ............. 6-19

Adjusting the throttle cable free play .................................... 6-19

Adjusting the valve clearance ...... 6-20

Tires ............................................. 6-20

Cast wheels ................................. 6-23

Accessories and replacement parts ......................................... 6-23

Adjusting the clutch lever free play .................................... 6-24

Adjusting the brake pedal position ..................................... 6-24

Adjusting the rear brake light switch ....................................... 6-25

Checking the front and rear brake pads .......................................... 6-25

Checking the brake fluid level ...... 6-26

Changing the brake fluid .............. 6-27

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 ............ 6-30

Checking and lubricating the centerstand and sidestand ....... 6-31

Lubricating the rear suspension ... 6-31

Checking the front fork ................. 6-31


Checking the steering ...................6-32

Checking the wheel bearings .......6-33

Battery ..........................................6-33

Replacing the fuses ......................6-34

Replacing a headlight bulb ...........6-35

Replacing a tail/brake light bulb ...6-36

Replacing a turn signal light bulb ...........................................6-37

Front wheel ...................................6-37

Rear wheel ...................................6-38

Troubleshooting ............................6-40

Troubleshooting charts .................6-41

MOTORCYCLE CARE AND

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

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

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

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

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

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

Reporting safety defects .................9-3

Motorcycle noise regulation ............9-4

Maintenance record ........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY ...............................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) .......................................9-9

TABLE OF CONTENTS


1

SAFETY INFORMATION

EAU10270

MOTORCYCLES ARE SINGLE

TRACK VEHICLES. THEIR SAFE USE

AND OPERATION ARE DEPENDENT

UPON THE USE OF PROPER RIDING

TECHNIQUES AS WELL AS THE EX-

PERTISE OF THE OPERATOR. EV-

ERY OPERATOR SHOULD KNOW

THE FOLLOWING REQUIREMENTS

BEFORE RIDING THIS MOTOR-

CYCLE.

HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT

●

SOURCE ON ALL ASPECTS OF

MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS AND

MAINTENANCE REQUIRE-

●

●

MENTS IN THE OWNER’S MAN-

UAL.

OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING

TECHNIQUES.

OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED

BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-

SARY BY MECHANICAL CONDI-

TIONS.

Safe riding

● Always make pre-operation checks. Careful checks may help

● prevent an accident.

This motorcycle is designed to car-

● ry the operator and a passenger.

The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents.

Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

1-1

●

●

• Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.

• Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.

• Know your skills and limits.

Staying within your limits may help you to avoid an accident.

• We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls.

Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn


●

● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).

• Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

• Always signal before turning or changing lanes. Make sure that other motorists can see you.

The posture of the operator and passenger is important for proper control.

• The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.

• The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.

• Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

Never ride under the influence of alcohol or other drugs.

● This motorcycle is designed for onroad use only. It is not suitable for off-road use.

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

●

●

Always wear an approved helmet.

Wear a face shield or goggles.

Wind in your unprotected eyes could contribute to an impairment

●

●

● of vision that could delay seeing a hazard.

The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.

Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.

Never touch the engine or exhaust system during or after operation.

They become very hot and can


● cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

A passenger should also observe the above precautions.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury.

Modifications may also make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories.

Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:

1

1-2


1


Loading

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of

188 kg (415 lb) (CAL)

189 kg (417 lb) (U49). When loading within this weight limit, keep the following in mind:

● Cargo and accessory weight should be kept as low and close to

● the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.

Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely

● attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response.

Accessories

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.

● Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

• Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories

1-3

● are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.

• Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles.

• Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended.

Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power.


Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

• Always turn the engine off when refueling.

• Take care not to spill any gasoline on the engine or exhaust system when refueling.

• Never refuel while smoking or in

● the vicinity of an open flame.

Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has ad-

● equate ventilation.

Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following:

• The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.

●

●

• Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

• Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire.

When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.

If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately.

If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.


1

1-4


1


Location of important labels

Please read the following important labels carefully before operating this vehicle.

EAU10381

1-5


1

CAUTION

Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield.

Use neutral detergent.

5JW-00

(5JW-2835Y-00)

2

3

4

6

1-6

7


5 California only

1

2


DESCRIPTION

Left view

EAU10410

1. Front fork compression damping force adjusting screw (page 3-11)

2. Front fork rebound damping force adjusting screw (page 3-11)

3. Front fork spring preload adjusting bolt (page 3-11)

4. Air filter element (page 6-17)

5. Fuses (page 6-34)

6. Storage compartment (page 3-11)

7. Grab bar

8. Seat lock/helmet holder (page 3-10/page 3-10)

9. Shock absorber assembly compression damping force adjusting screw

(page 3-13)

10.Shock absorber assembly spring preload adjusting ring (page 3-13)

11.Shock absorber assembly rebound damping force adjusting knob

(page 3-13)

12.Shift pedal (page 3-7)

2-1


Right view

1. Owner’s tool kit (page 6-1)

2. Rear brake fluid reservoir (page 6-26)

3. Battery (page 6-33)

4. Front brake fluid reservoir (page 6-26)

5. Radiator cap (page 6-14)

6. Engine oil filter cartridge (page 6-12)

7. Engine oil level check window (page 6-12)

8. Brake pedal (page 3-7)

2-2

9. Coolant reservoir (page 6-14)

DESCRIPTION

EAU10420

2

2


DESCRIPTION

Controls and instruments

1. Clutch lever (page 3-6)

2. Left handlebar switches (page 3-5)

3. Starter (choke) lever (page 3-9)

4. Speedometer unit (page 3-3)

5. Main switch/steering lock (page 3-1)

6. Tachometer unit (page 3-4)

7. Fuel gauge (page 3-5)

8. Right handlebar switches (page 3-5)

2-3

9. Brake lever (page 3-7)

10.Throttle grip (page 6-19)

EAU10430


INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock

EAU10460 EAU10680

LOCK

The steering is locked, and all electrical systems are off. The key can be removed.

To unlock the steering

To lock the steering

3

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.

EAU10510

ON

All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed.

EAU10660

OFF

All electrical systems are off. The key can be removed.

1. Push.

2. Turn.

1. Turn the handlebars all the way to the left.

2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it.

3. Remove the key.

1. Push.

2. Turn.

Push the key in, and then turn it to

“OFF” while still pushing it.

EWA10060

WARNING

Never turn the key to “OFF” or

“LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or

“LOCK”.

3-1


3


EAU11001

Indicator and warning lights

High beam indicator light “ ”

EAU11080

This indicator light comes on when the high beam of the headlight is switched on.

1. Left turn signal indicator light “ ”

2. Neutral indicator light “ ”

3. High beam indicator light “

4. Oil level warning light “ ”

”

5. Right turn signal indicator light “ ”

6. Coolant temperature warning light “ ”

7. Fuel level warning light “ ”

EAU11030

Turn signal indicator lights “ ” and

“ ”

The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.

EAU11120

Oil level warning light “ ”

This warning light comes on when the engine oil level is low.

The electrical circuit of the warning light can be checked by turning the key to

“ON”.

If the warning light does not come on for a few seconds, then go off, have a

Yamaha dealer check the electrical circuit.

NOTE:

Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction.

EAU11060

Neutral indicator light “ ”

This indicator light comes on when the transmission is in the neutral position.

EAU11350

Fuel level warning light “ ”

This warning light comes on when the fuel level drops below approximately

4.0 L (1.06 US gal) (0.88 Imp.gal).

When this occurs, refuel as soon as possible.


“ON”.



EAU11440

Coolant temperature warning light

“ ”

This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool.


“ON”.



3-2



ECA10020

CAUTION:

Do not operate the engine if it is overheated.

Speedometer unit

EAU11810 be traveled on a full tank of fuel. This information will enable you to plan future fuel stops.

To set a mode

Push the “SELECT” button to change between the odometer mode “ODO”, and the tripmeter modes “TRIP 1” and

“TRIP 2” in the following order:

ODO → TRIP 1 → TRIP 2 → ODO

1. Speedometer

2. Odometer/tripmeter

3. “SELECT” button

4. “RESET” button

The speedometer unit is equipped with the following:

●

● an odometer two tripmeters

When set to “ODO”, the vehicle’s total mileage is indicated.

When set to “TRIP 1” or “TRIP 2”, the vehicle’s mileage since the tripmeter was last reset is indicated. The tripmeters can be used together with the fuel gauge to estimate the distance that can

To reset a meter

To reset either tripmeter 1 or 2 to 0.0, select either by pushing the “SELECT” button, and then push the “RESET” button for at least one second.

3

3-3


3


Tachometer unit

1. Tachometer

2. Tachometer red zone

3. Clock

The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.

ECA10030

CAUTION:

Do not operate the engine in the tachometer red zone.

Red zone: 11500 r/min and above

This tachometer unit is equipped with a clock.

EAU11890 To set the clock

1. Push both the “SELECT” and “RE-

SET” 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.

EAU12100

Self-diagnosis devices

This model is equipped with a self-diagnosis device for the following electrical circuits:

●

●

●

● throttle position sensor speed sensor

EXUP system overturn switch

If any of those circuits are defective, the tachometer will repeatedly display the following error code:

0 r/min for

3 seconds

Circuit-specific number of r/min for 2.5 seconds

(See the table below.)

Current engine speed for

3 seconds

Use the chart below to identify the faulty electrical circuit.

Specific r/min for the faulty circuit

Throttle position sensor:

3000 r/min

Speed sensor:

4000 r/min

EXUP system:

7000 r/min

Overturn switch:

9000 r/min

3-4



If the tachometer displays such an error code, note the circuit-specific number of r/min, and then have a Yamaha dealer check the vehicle.

ECA10040

CAUTION:

When the tachometer displays an error code, the vehicle should be checked as soon as possible in order to avoid engine damage.

Fuel gauge

EAU12110

Handlebar switches

Left

EAU12341

3

1. Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches

“E”, approximately 4.0 L (1.06 US gal)

(0.88 Imp.gal) of fuel remain in the fuel tank. If this occurs, refuel as soon as possible.

NOTE:

Do not allow the fuel tank to empty itself completely.

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “ ”

Right

1. Engine stop switch “ / ”

2. Start switch “ ”

3-5


3


EAU12400

Dimmer switch “ / ”

Set this switch to “ ” for the high beam and to “ ” for the low beam.

ECA10050

CAUTION:

See page 5-1 for starting instruc-

tions prior to starting the engine.

EAU12460

Turn signal switch “ / ”

To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position.

or when the throttle cable is stuck.

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ”

Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns

Clutch lever

EAU12820

1. Clutch lever

The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.

The clutch lever is equipped with a clutch switch, which is part of the igni-

tion circuit cut-off system. (See page

3-16.)

EAU12710

Start switch “ ”

Push this switch to crank the engine with the starter.

3-6


Shift pedal


EAU12941 EAU12870 EAU12930

Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.

Brake pedal

3

1. Shift pedal

The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle.

1. Brake lever

2. Brake lever position adjusting dial

3. Arrow mark

4. Distance between brake lever and handlebar grip

The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the handlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever.

3-7

1. Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.


3


Fuel tank cap

EAU13070

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.

EWA11090

WARNING

Make sure that the fuel tank cap is properly closed before riding.

Fuel

1. Fuel tank cap lock cover

2. Unlock.

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.

To close the fuel tank cap

1. Push the fuel tank cap into position with the key inserted in the lock.

2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover.

EAU13210

1. Fuel tank filler tube

2. Fuel level

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

EWA10880

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.

3-8



ECA10070

CAUTION:

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

21.0 L (5.55 US gal) (4.62 Imp.gal)

Fuel reserve amount:

4.0 L (1.06 US gal) (0.88 Imp.gal)

EAU13300 knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

ECA11400

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number

[(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If

Starter (choke) lever “ ”

EAU13590

1. Starter (choke) lever “ ”

Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).

Move the lever in direction (a) to turn on the starter (choke).

Move the lever in direction (b) to turn off the starter (choke).

3-9

3



EAU13940

Seat

To remove the seat

1. Insert the key into the seat lock, and then turn it clockwise.

Helmet holder

EAU14290

3

1. Seat lock

2. Unlock.

2. While holding the key in that position, lift the rear of the seat, and then pull the seat off.

1. Projection

2. Seat holder

2. Push the rear of the seat down to lock it in place.

3. Remove the key.

NOTE:

Make sure that the seat is properly secured before riding.

To install the seat

1. Insert the projection on the front of the seat into the seat holder as shown.

1. Helmet holder

2. Unlock.

To open the helmet holder, insert the key into the lock, and then turn the key as shown.

To lock the helmet holder, turn the key to the original position, and then remove it.

EWA10160

WARNING

Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.

3-10


Storage compartment

1. Storage compartment

The storage compartment is located

under the seat. (See page 3-10.)

EWA10960

WARNING

●

●

Do not exceed the load limit of 3 kg (7 lb) for the storage compartment.

Do not exceed the maximum load of FZS1000:189 kg (417 lb)

/ FZS1000C: 188 kg (415 lb) for the vehicle.

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.


EAU14450 When washing the vehicle, be careful not to let any water enter the storage compartment.

EAU14750

Adjusting the front fork

This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws.

EWA10180

WARNING

Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.

Spring preload

1. Spring preload adjusting bolt

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 pre-

3-11

3


3

INSTRUMENT AND CONTROL FUNCTIONS load 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.

Rebound damping force Compression damping force

1. Current setting

2. Front fork cap bolt

Spring preload setting:

Minimum (soft):

5*

Standard:

2

Maximum (hard):

1

* Adjusting bolt fully turned in direction

(b)

1. Rebound damping force adjusting screw

To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw on each fork leg in direction (b).

1. Compression damping force adjusting screw

To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw on each fork leg in direction (b).

Rebound damping setting:

Minimum (soft):

17 clicks in direction (b)*

Standard:


Maximum (hard):


* With the adjusting screw fully turned in direction (a)

Compression damping setting:

Minimum (soft):


Standard:


Maximum (hard):


* With the adjusting screw fully turned in direction (a)

3-12



ECA10100

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.

EAU15041

Adjusting the shock absorber assembly

This shock absorber assembly is equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression damping force adjusting screw.

CAUTION:

ECA10100

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

Spring preload

To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b).

NOTE:

● Align the appropriate notch in the adjusting ring with the position in-

● dicator on the shock absorber.

Use the special wrench included in the owner’s tool kit to make the adjustment.

Spring preload setting:

Minimum (soft):

1

Standard:

6

Maximum (hard):

11

3

1. Spring preload adjusting ring

2. Special wrench

3. Position indicator

3-13


3


Rebound damping force

1. Rebound damping force adjusting knob

To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob in direction

(a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob in direction (b).

Rebound damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:


Maximum (hard):


* With the adjusting knob fully turned in direction (a)

Compression damping force

1. Compression damping force adjusting screw

To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).

Compression damping setting:

Minimum (soft):

1 click(s) in direction (a)*

Standard:


Maximum (hard):


* With the adjusting screw fully turned in direction (b)

NOTE:

Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary.

EWA10220

WARNING

This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

● Do not tamper with or attempt to open the gas cylinder.

3-14



●

●

●

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.

EAU15280

EXUP system

This model is equipped with Yamaha’s

EXUP (EXhaust Ultimate Power valve) system. This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe.

The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor.

ECA10190

CAUTION:

●

●

The EXUP system has been set and extensively tested at the

Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.

If the EXUP system does not operate, have a Yamaha dealer check it.

EAU15300

Sidestand

The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.

NOTE:

The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.

(See further down for an explanation of the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up

(or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.

Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described

3

3-15


3

INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly.

EAU15321

Ignition circuit cut-off system

The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions.

● It prevents starting when the transmission is in gear and the side-

● stand is up, but the clutch lever is not pulled.

It prevents starting when the transmission is in gear and the clutch le-

● ver is pulled, but the sidestand is still down.

It cuts the running engine when the transmission is in gear and the sidestand is moved down.

Periodically check the operation of the ignition circuit cut-off system according to the following procedure.

EWA10260

WARNING

●

●

The vehicle must be placed on the centerstand during this inspection.

If a malfunction is noted, have a

Yamaha dealer check the system before riding.

3-16



With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is turned on.

3. Turn the key on.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES

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

NO

NO

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 NO

The system is OK. The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden until checked by a Yamaha dealer.

The sidestand switch may be defective.


The clutch switch may be defective.


3

3-17


4

PRE-OPERATION CHECKS

EAU15591

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

EWA11150

WARNING

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

4-1



EAU15601

Pre-operation check list

ITEM

Fuel

Engine oil

Coolant

Front brake

Rear brake

Clutch

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 brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

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

• Check hydraulic system for leakage.


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

• Check brake pads for wear.


• Check fluid level in reservoir.

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

• Check hydraulic system for leakage.


• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

PAGE

3-8

6-12

6-14

6-25, 6-26

6-24, 6-25, 6-26

6-24

4

4-2


4


Throttle grip

ITEM

Control cables

Drive chain

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Centerstand, sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch

CHECKS

• Make sure that operation is smooth.

• Check cable free play.

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


• 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.


• Lubricate pedal pivoting points if necessary.


• Lubricate lever pivoting points if necessary.


• Lubricate pivots if necessary.

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

• Tighten if necessary.



• Check operation of ignition circuit cut-off system.

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

PAGE

6-19, 6-30

6-29

6-27, 6-29

6-20, 6-23

—

—

3-15

6-30

6-30

6-31

4-3


OPERATION AND IMPORTANT RIDING POINTS

EAU15950

●

●

●

EWA10270

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.

EAU16210

Starting and warming up a cold engine

In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met:

● The transmission is in the neutral

● position.

The transmission is in gear with the clutch lever pulled and the sidestand up.

EWA10290

WARNING

●

●

Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure

described on page 3-16.

Never ride with the sidestand down.

1. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”.

ECA11430

CAUTION:

The oil level warning light, coolant temperature warning light and fuel level warning light should come on for a few seconds, then go off. If a warning light does not go off, have a

Yamaha dealer check the electrical circuit.


NOTE:

When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a


3. Turn the starter (choke) on and

completely close the throttle. (See page 3-9.)

4. Start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

5-1

5


5


ECA11490

CAUTION:

●

●

If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting with sufficient engine oil, have a


If the coolant temperature warning light flickers or remains on after starting, immediately stop the engine, and then check the coolant level and the vehicle for coolant leakage. If necessary, add coolant, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting

● with sufficient coolant, have a


If the fuel level warning light remains on after starting, stop the engine, and then check the fuel level. If necessary, refuel as soon as possible, and then check the warning light again. If, when the key is turned to “ON”, the warning light does not come on for a few seconds, then go off, or if it does not go off after starting with sufficient fuel, have a Yamaha dealer check the electrical circuit.

5. After starting the engine, move the starter (choke) back halfway.

ECA11130

CAUTION:

For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!

6. When the engine is warm, turn the starter (choke) off.

NOTE:

The engine is warm when it responds normally to the throttle with the starter

(choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about

10 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter

(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.

5-2



EAU16640

Starting a warm engine

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.

Shifting

EAU16671

CAUTION:

●

● 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.

ECA10260

Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage

1. Shift pedal

2. Neutral position

Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.

The gear positions are shown in the illustration.

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.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage the clutch.

2. Shift the transmission into first gear. The neutral indicator light should go out.

3. Open the throttle gradually, and at the same time, release the clutch lever slowly.

5-3

5


5


4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.

5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)

6. Open the throttle part way and gradually release the clutch lever.

7. Follow the same procedure when shifting to the next higher gear.

NOTE:

Always shift gears at the recommended shift points.

EAU16700

To decelerate

1. Apply both the front and the rear brakes to slow the motorcycle.

2. Shift the transmission into first gear when the motorcycle reaches

25 km/h (15.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle.

3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

EAU16740

Recommended shift points

The recommended shift points during acceleration and deceleration are shown in the table below.

Shift up points:

1st → 2nd: 16 km/h (9.9 mi/h)

2nd → 3rd: 24 km/h (14.9 mi/h)

3rd

→ 4th: 32 km/h (19.9 mi/h)

4th → 5th: 40 km/h (24.9 mi/h)

5th → 6th: 48 km/h (29.8 mi/h)

Shift down points:

6th → 5th: 25 km/h (15.5 mi/h)

5th → 4th: 25 km/h (15.5 mi/h)

4th

→ 3rd: 25 km/h (15.5 mi/h)

3rd → 2nd: 25 km/h (15.5 mi/h)

2nd → 1st: 25 km/h (15.5 mi/h)

EAU16841

Engine break-in

There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully.

Since the engine is brand new, do not put an excessive load on it for the first

1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.

During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.

EAU17091

0–1000 km (0–600 mi)

Avoid prolonged operation above 5000 r/min.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 6000 r/min.

5-4



ECA10301

CAUTION:

After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced.

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

ECA10310

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.

EAU17200

Parking

When parking, stop the engine, and then remove the key from the main switch.

EWA10310

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 vehicle may overturn.

5

5-5


6

PERIODIC MAINTENANCE AND MINOR REPAIR

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWA10320

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU17231 EAU17300

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR MOTORCYCLE IS IMPOR-

TANT IN ORDER TO ENJOY LONG,

PLEASURABLE SERVICE. ESPE-

CIALLY IMPORTANT ARE THE MAIN-

TENANCE SERVICES RELATED TO

EMISSIONS CONTROL. THESE

CONTROLS NOT ONLY FUNCTION

TO ENSURE CLEANER AIR, BUT

ARE ALSO VITAL TO PROPER EN-

GINE OPERATION AND MAXIMUM

PERFORMANCE. IN THE FOLLOW-

ING PERIODIC MAINTENANCE

CHARTS, THE SERVICES RELATED

TO EMISSIONS CONTROL ARE

GROUPED SEPARATELY. THESE

SERVICES REQUIRE SPECIALIZED

DATA, KNOWLEDGE, AND EQUIP-

MENT. YAMAHA DEALERS ARE

TRAINED AND EQUIPPED TO PER-

FORM THESE PARTICULAR SER-

VICES.

Owner’s tool kit

EAU17510

1. Owner’s tool kit

The owner’s tool kit is located inside the storage compartment under the seat.

(See page 3-10.)

The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

6-1


EWA10340

WARNING

Modifications not approved by

Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use.

Consult a Yamaha dealer before attempting any changes.


6

6-2


6


EAU17600

Periodic maintenance chart for the emission control system

INITIAL

No.

ITEM ROUTINE

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

1

2

3

4

5

6

7

8

*

*

*

*

*

*

*

Fuel line

Fuel filter

Spark plugs

Valve clearance

Crankcase breather system

Carburetor synchronization

Idle speed

Exhaust system

9 *

Evaporative emission control system

(For California only)

• Check fuel and vacuum hoses for cracks or damage.


• Replace.

• Check condition.

• Adjust gap and clean.

• Replace every 8000 mi (13000 km) or 12 months.

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.


• Adjust synchronization of carburetors.

• Check and adjust engine idle speed.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check control system for damage.


√

√

√

√

√

√

√

√

Replace.

√

√

Every 26600 mi (42000 km)

√

√

√

√

√

√

√

√

√

√

Replace.

√

√

√

√

√

Replace.

√

√

√

√

√

√

6-3



No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months


8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

10 *

Air induction system

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

• Replace any damaged parts.

√ √

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

√ √ √

6

6-4


6


EAU32181

General maintenance and lubrication chart

No.

1 * Air filter element

2 * Clutch

3 * Front brake

4 * Rear brake

5 * Brake hoses

6 * Wheels

7 * Tires

ITEM

8 * Wheel bearings

ROUTINE

• Clean with compressed air.



• Adjust or replace cable.

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

• Replace brake pads if necessary.

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

• Replace brake pads if necessary.

• Check for cracks or damage.

• Replace.

• Check runout and for damage.


• Check tread depth and for damage.


• Check air pressure.


• Check bearings for smooth operation.


INITIAL

600 mi

(1000 km) or

1 month


4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

√ √ √ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Every 4 years

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

6-5



No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month


4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

9

10

11 *

12 *

13

14

*

15 *

16 *

Swingarm pivot bearings

Drive chain

Steering bearings

Chassis fasteners

Brake and clutch lever pivot shafts

Brake and shift pedal pivot shafts

Centerstand and sidestand pivots

Sidestand switch

• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease.

• Check chain slack/alignment and condition.

• Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

• Check bearing assembly for looseness.

• Moderately repack with lithiumsoap-based grease every 10000 mi (16000 km) or 18 months.

• Check all chassis fitting and fasteners.


• Apply lithium-soap-based grease

(all-purpose grease) lightly.






• Check operation and replace if necessary.

√

Repack.

Every 600 mi (1000 km) and after washing the motorcycle or riding in the rain

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Repack.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

6

6-6


6


No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months


8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

17 *

18 *

19 *

20

Front fork

Shock absorber assembly

Rear suspension link pivots

Engine oil

• Check operation and for oil leakage.


• Check operation and for oil leakage.


• Apply lithium-soap-based grease lightly.

• Change (warm engine before draining).

√

√

√

√

√

√

√

21 *

Engine oil filter cartridge

• Replace.

√ √

22 * Cooling system

• Check hoses for cracks or damage.


• Change with ethylene glycol antifreeze coolant every 24 months.

√ √

23 * Control cables

• Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly.

√ √ √

24 *

Throttle grip housing and cable

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

√ √

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

√

√

√

√

√

√

√

√

√

√

√

√

Change.

√

√

√

√

√

√

√

√

6-7



NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

EAU17630

NOTE:

●

●

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

Hydraulic brake service

• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

6

6-8


6


Removing and installing panels

EAU18770 The 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 panel needs to be removed and installed.

1. Panel A

2. Panel B

EAU19292

Panels A and C

To remove one of the panels

Remove the screw, and then pull the panel off as shown.

1. Panel C

2. Screw

To install the panel

Place the panel in the original position, and then install the screw.

1. Panel A

2. Screw

1. Panel C

6-9



Panel B

1. Panel B

2. Screw

EAU19210

To remove the panel

Remove the screws, and then take the panel off.

To install the panel

Place the panel in the original position, and then install the screws.

Checking the spark plugs

EAU19543

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.

1. Spark plug wrench

To remove a spark plug

1. Remove the spark plug cap.

1. Spark plug cap

2. 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 vehicle is ridden normally).

2. Check that all spark plugs installed in the engine have the same color.

NOTE:

If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a

Yamaha dealer check the vehicle.

6

6-10


6


3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

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.

Specified spark plug:

NGK/CR9E

DENSO/U27ESR-N

To install a spark plug

1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

4. Install the spark plug cap.

EAU19671

Canister (for California only)

This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere.

●

●

Check each hose connection.

Check each hose and canister for

● cracks or damage. Replace if damaged.

Make sure the vent hose is not blocked. Clean it if necessary.

1. Spark plug gap

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

6-11



EAU19890

Engine oil and oil filter cartridge

The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart.

NOTE:

The engine oil should be between the minimum and maximum level marks.

2. Place an oil pan under the engine to collect the used oil.

3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase.

To check the engine oil level

1. Place the vehicle on the centerstand.

NOTE:

Make sure that the vehicle is positioned straight up when checking the oil level.

A slight tilt to the side can result in a false reading.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-right side of the crankcase.

1. Engine oil filler cap

2. Engine oil level check window

3. Maximum level mark

4. Minimum level mark

4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

To change the engine oil (with or without oil filter cartridge replacement)

1. Start the engine, warm it up for several minutes, and then turn it off.

6-12

1. Engine oil drain bolt

NOTE:

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

● tridge is not being replaced.

When draining the engine oil, use a funnel or similar device to keep the oil away from the exhaust pipe.

4. Remove the oil filter cartridge with an oil filter wrench.

6



6

1. Oil filter wrench

2. Oil filter cartridge

1. O-ring

NOTE:

An oil filter wrench is available at a

Yamaha dealer.

5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.

NOTE:

Make sure that the O-ring is properly seated.

6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.

1. Torque wrench


Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

7. Install the engine oil drain bolt, and then tighten it to the specified torque.


Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.

6-13



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.

EAU20070

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge replacement:

2.80 L (2.96 US qt) (2.46 Imp.qt)

With oil filter cartridge replacement:

3.00 L (3.17 US qt) (2.64 Imp.qt)

ECA11620

CAUTION:

●

●

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled

“ENERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

NOTE:

After the engine is started, the engine oil level warning light should go off if the oil level is sufficient.

ECA10400

CAUTION:

If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle.

10. Turn the engine off, and then check the oil level and correct it if necessary.

EAU20101

To check the coolant level

1. Place the vehicle on the centerstand.

NOTE:

● The coolant level must be checked on a cold engine since the level varies with engine temperature.

● Make sure that the vehicle is positioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading.

2. Check the coolant level in the coolant reservoir.

NOTE:

The coolant should be between the minimum and maximum level marks.

6

6-14


6


1. Coolant reservoir

2. Maximum level mark


3. If the coolant is at or below the minimum level mark, remove pan-

el A (See page 6-9.), remove the

reservoir cap, add coolant to the maximum level mark, and then install the reservoir cap and the panel.

Coolant reservoir capacity (up to the maximum level mark):

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

ECA10470

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.

EWA10380

WARNING

Never attempt to remove the radiator cap when the engine is hot.

NOTE:

● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator.

● If the engine overheats, see page

6-41 for further instructions.

EAU20431

To change the coolant

1. Place the vehicle on the centerstand and let the engine cool if necessary.

2. Remove panels A and B. (See page 6-9.)

3. Place a container under the engine to collect the used coolant.

4. Remove the radiator cap.

WARNING

Never attempt to remove the radiator cap when the engine is hot.

EWA10380

6-15


1. Radiator cap

5. Remove the coolant drain bolt to drain the cooling system.

1. Coolant drain bolt

6. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water.


7. Install the coolant drain bolt, and then tighten it to the specified torque.

NOTE:

Check the washer for damage and replace it if necessary.


Coolant drain bolt:

7 Nm (0.7 m·kgf, 5 ft·lbf)

8. Pour the recommended coolant into the radiator until it is full.

Recommended antifreeze:

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Antifreeze/water mixture ratio:

1:1

Coolant quantity:

Radiator capacity (including all routes):

2.40 L (2.54 US qt) (2.11 Imp.qt)

Coolant reservoir capacity:

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

ECA10470

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.

9. Install the radiator cap, start the engine, let it idle for several minutes, and then turn it off.

10. Remove the radiator cap to check the coolant level in the radiator. If necessary, add sufficient coolant

6

6-16

6


PERIODIC MAINTENANCE AND MINOR REPAIR until it reaches the top of the radiator, and then install the radiator cap.

11. Check the coolant level in the reservoir. If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap.

12. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system.

13. Install the panels.

EAU20681

Cleaning the air filter element

The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.

Clean the air filter element more frequently if you are riding in unusually wet or dusty areas.

1. Remove the seat. (See page

3-10.)

2. Remove the fuel tank bolts.

● Do not tilt or pull the fuel tank too much, otherwise the fuel hoses may come loose, which could cause fuel leakage.

4. Remove panels A and C. (See page 6-9.)

5. Pull the rubber cover off its holders.

1. Bolt

3. Lift the fuel tank to position it away from the air filter case. (Do not disconnect the fuel hoses!)

EWA10410

WARNING

● Make sure that the fuel tank is well supported.

6-17

1. Rubber cover

2. Rubber cover holder

6. Remove the air filter case cover by removing the screws.


PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown.

If the air filter element is damaged, replace it.

1. Air filter case cover

2. Screw

7. Pull the air filter element out.

1. Air filter element

8. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt

1. Air filter element

9. Insert the air filter element into the air filter case.

ECA11330

CAUTION:

The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.

10. Install the air filter case cover by installing the screws.

11. Place the rubber cover in the original position.

12. Install the panels.

13. Install the fuel tank by installing the bolts.

EWA11290

WARNING

●

●

●

Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, otherwise fuel may leak.

Make sure that the fuel hoses are properly connected and routed, and not pinched.

Be sure to place the fuel tank breather hose in the original position.

1. Fuel tank breather hose

2. Original position (white mark)

6-18

6

6



14. Install the seat.

Adjusting the carburetors

EAU21270

The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.

EAU21380

Adjusting the throttle cable free play

1. Throttle cable free play

The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

6-19



EAU21400

Adjusting the valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

EAU21750

Tires

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.

Tire air pressure

The tire air pressure should be checked and, if necessary, adjusted before each ride.

EWA10500

WARNING

●

●

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.

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

270 kPa (39 psi) (2.70 kgf/cm²)

90–188 kg (198–415 lb) (CAL)

90–189 kg (198–417 lb) (U49):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

Maximum load*:

188 kg (415 lb) (CAL)

189 kg (417 lb) (U49)

* Total weight of rider, passenger, cargo and accessories

EWA10510

WARNING

Proper loading of your vehicle is important for several characteristics of your vehicle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heavi-

6-20

6


6

PERIODIC MAINTENANCE AND MINOR REPAIR est items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVER-

LOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories

(cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury.

Tire inspection

1. Tire sidewall

2. Tire wear indicator

3. Tire tread depth

Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced.

●

●

EWA10580

WARNING

It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.

The replacement of all wheeland brake-related parts, including the tires, should be left to a

Yamaha dealer, who has the necessary professional knowledge and experience.

Tire information

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)

1. Tire air valve

2. Tire air valve core

3. Tire air valve cap with seal

6-21



This motorcycle is equipped with cast wheels and tubeless tires with valves.

EWA10480

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.

Front tire:

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

BRIDGESTONE/BT020F U

Rear tire:

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

BRIDGESTONE/BT020R U

FRONT and REAR:

Tire air valve:

TR412

Valve core:

#9000A (original)

EWA10600

WARNING

This motorcycle is fitted with superhigh-speed tires. Note the following points in order to make the most efficient use of these tires.

● Use only the specified replace-

● ment 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 high-

6-22

●

● speed riding to ride conservatively for approximately 100 km

(60 mi) after installing a new tire.

The tires must be warmed up before a high-speed run.

Always adjust the tire air pressure according to the operating conditions.

6


6


EAU21960

Cast wheels

To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels.

● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the

● wheel. A deformed or cracked wheel must be replaced.

The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a short-

● ened tire life.

Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

EAU22010

Accessories and replacement parts

EWA10620

WARNING

This motorcycle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your motorcycle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle. Please consider Genuine Yamaha Parts and Accessories before making a purchase. Use of non-Yamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies,

Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha.

6-23



EAU22080

Adjusting the clutch lever free play

NOTE:

If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism.

Adjusting the brake pedal

EAU22240

position

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.

To increase the clutch lever free play, turn the adjusting bolt in direction (a).

To decrease the clutch lever free play, turn the adjusting bolt in direction (b).

1. Distance between brake pedal and footrest

The top of the brake pedal should be positioned approximately 43.0 mm

(1.69 in) below the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, have a

Yamaha dealer adjust it.

EWA10690

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

6

6-24

6


PERIODIC MAINTENANCE AND MINOR REPAIR the braking performance, which may result in loss of control and an accident.

EAU22270

Adjusting the rear brake light switch

EAU22321

Checking the front and rear brake pads

Front brake

1. Rear brake light switch

2. Rear brake light switch adjusting nut

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).

1. Brake pad wear indicator groove

Rear brake

1. Brake pad wear indicator groove

6-25



The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Front brake

EAU22580

Checking the brake fluid level


Rear brake

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.

Observe these precautions:

● When checking the fluid level, make sure that the top of the brake

● fluid reservoir is level.

Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Recommended brake fluid:

DOT 4

● Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.


Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.

6

6-26


6


●

●

●

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.

EAU22730

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.

● Oil seals: Replace every two years.

● Brake hoses: Replace every four years.

EAU22760

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU22790

To check the drive chain slack

1. Place the motorcycle on the centerstand.


3. Spin the rear wheel several times to locate the tightest portion of the drive chain.

4. Measure the drive chain slack as shown.

Drive chain slack:

40.0–50.0 mm (1.57–1.97 in)

6-27



NOTE:

Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment.

3. Tighten the locknuts, and then tighten the axle nut to the specified torque.


Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lbf)

1. Drive chain slack

5. If the drive chain slack is incorrect, adjust it as follows.

EAU22940

To adjust the drive chain slack

1. Loosen the axle nut and the locknut on each side of the swingarm.

2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting bolt on each side of the swingarm in direction (b), and then push the rear wheel forward.

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Alignment marks

ECA10570

CAUTION:

Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

6-28

6


6


EAU23020

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.

ECA10580

CAUTION:

The drive chain must be lubricated after washing the motorcycle or riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

ECA11120

CAUTION:

To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

ECA11110

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.

EAU23090

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.

Recommended lubricant:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE)

EWA10710

WARNING

Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

6-29



EAU23110

Checking and lubricating the throttle grip and cable

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.

EAU23131

Checking and lubricating the brake and shift pedals

EAU23140

Checking and lubricating the brake and clutch levers

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.


Lithium-soap-based grease (all-purpose grease)

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.



6

6-30


6


EAU23210

Checking and lubricating the centerstand and sidestand

EAU23250

Lubricating the rear suspension

The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

EAU23271

Checking the front fork

The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.


Lithium-soap-based grease

To check the condition

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

Check the inner tubes for scratches, damage and excessive oil leakage.

The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.

EWA10740

WARNING

If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

To check the operation

1. Place the vehicle on a level surface and hold it in an upright position.

2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.



6-31



ECA10590

CAUTION:

If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.

EAU23280

Checking the steering

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.

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.

6

6-32


6


EAU23290

Checking the wheel bearings

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.

EAU23370

Battery

This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.

ECA10620

CAUTION:

Never attempt to remove the battery cell seals, as this would permanently damage the battery.

●

EWA10760

WARNING

Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.

• EXTERNAL: Flush with plenty of water.

• INTERNAL: Drink large quantities of water or milk and immediately call a physician.

●

●

• EYES: Flush with water for 15 minutes and seek prompt medical attention.

Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

KEEP THIS AND ALL BATTER-

IES 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 vehicle is equipped with optional electrical accessories.

To store the battery

1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

6-33



2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.

3. Fully charge the battery before installation.

4. After installation, make sure that the battery leads are properly connected to the battery terminals.

ECA10630

CAUTION:

●

●

Always keep the battery charged. Storing a discharged battery can cause permanent battery damage.

To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required.

Using a conventional battery charger will damage the battery.

If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.

Replacing the fuses

EAU23622

1. Main fuse

2. Headlight fuse

3. Radiator fan fuse

4. Ignition fuse

5. Signaling system fuse

6. Backup fuse (for odometer and clock)

7. Spare fuse

8. Spare main fuse

The main fuse and the fuse box, which contains the fuses for the individual cir-

cuits, are located under the seat. (See page 3-10.)

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off the electrical circuit in question.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

6-34

Specified fuses:

Main fuse:

30.0 A

Headlight fuse:

20.0 A

Radiator fan fuse:

10.0 A

Ignition fuse:

20.0 A

Signaling system fuse:

20.0 A

Backup fuse:

10.0 A

ECA10640

CAUTION:

Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.

3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

6


6


EAU23730

Replacing a headlight bulb

This model is equipped with two quartz bulb headlights. If a headlight bulb burns out, replace it as follows.

1. Remove panel B. (See page 6-9.)

2. Disconnect the headlight coupler, and then remove the bulb cover.

1. Headlight bulb cover

2. Headlight coupler

3. Unhook the headlight bulb holder, and then remove the defective bulb.

1. Headlight bulb holder

EWA10790

WARNING

Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.

4. Place a new headlight bulb into position, and then secure it with the bulb holder.

ECA10650

CAUTION:

Take care not to damage the following parts:

●

●

Headlight bulb

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

Headlight lens

Do not affix any type of tinted film or stickers to the headlight lens.

Do not use a headlight bulb of a wattage higher than specified.

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

6-35



5. Install the headlight bulb cover, and then connect the coupler.

6. Install the panel.

7. Have a Yamaha dealer adjust the headlight beam if necessary.

EAU24160

Replacing a tail/brake light bulb

1. Remove the seat. (See page

3-10.)

2. Remove the tail/brake light bulb cover.

1. Tail/brake light bulb cover

3. Remove the socket (together with the bulb) by turning it counterclockwise.

1. Tail/brake light bulb socket

4. Remove the defective bulb by pushing it in and turning it counterclockwise.

5. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

6. Install the socket (together with the bulb) by turning it clockwise.

7. Install the bulb cover.

8. Install the seat.

6

6-36


6


EAU24201

Replacing a turn signal light bulb

1. Remove the turn signal light lens by removing the screw.

1. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

4. Install the lens by installing the screw.

ECA11190

CAUTION:

Do not overtighten the screw, otherwise the lens may break.

Front wheel

EAU24360

EAU24470

To remove the front wheel

●

●

EWA10820

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.


2. Loosen the front wheel axle pinch bolt, then the wheel axle and the brake caliper bolts.

1. Wheel axle

2. Front wheel axle pinch bolt

3. Remove the brake hose holder on each side by removing the bolts.

4. Remove the brake caliper on each side by removing the bolts.

1. Bolt

2. Brake hose holder

3. Bolt

4. Brake caliper

ECA11050

CAUTION:

Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut.

5. Pull the wheel axle out, and then remove the wheel.

6-37


EAU25020

To install the front wheel

1. Lift the wheel up between the fork legs.

2. Insert the wheel axle.

3. Lower the front wheel so that it is on the ground.

4. Install the brake calipers by installing the bolts.

NOTE:

Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs.

5. Install the brake hose holders by installing the bolts.

6. Tighten the wheel axle, the wheel axle pinch bolt and the brake caliper bolts to the specified torques.


7. Push down hard on the handlebar several times to check for proper fork operation.

Rear wheel

EAU25080

EAU25201

To remove the rear wheel

●

●

EWA10820

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 axle nut and the brake caliper bolts.

Tightening torques:

Wheel axle:

72 Nm (7.2 m·kgf, 52 ft·lbf)

Front wheel axle pinch bolt:

19 Nm (1.9 m·kgf, 13 ft·lbf)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

1. Axle nut


6

6-38



3. Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt.

6. Turn the drive chain slack adjusting bolts fully in direction (a).

7. Push the wheel forward, and then remove the drive chain from the rear sprocket.

EAU25841

To install the rear wheel

1. Place the wheel and the brake caliper bracket in the original position.

2. Insert the wheel axle through the brake caliper bracket and wheel from the right-hand side, and then install the axle nut.

3. Install the drive chain onto the rear sprocket, and then adjust the drive

chain slack. (See page 6-27.)

6

1. Bolt

2. Brake torque rod

3. Brake torque rod bolt

4. Brake torque rod nut

5. Brake caliper bracket

4. Remove the axle nut, then the brake caliper by removing the bolts.

ECA11300

CAUTION:

Do not apply the brake after the brake caliper has been removed, otherwise the brake pads will be forced shut.

5. Loosen the locknut on each side of the swingarm.

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

NOTE:

The drive chain does not need to be disassembled in order to remove and install the rear wheel.

8. While supporting the wheel, pull the wheel axle out.

9. Remove the wheel.

6-39

4. Connect the brake torque rod to the brake caliper bracket by installing the bolt and the nut.

5. Install the brake caliper by installing the bolts.



NOTE:

Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc.

6. Take the motorcycle off the centerstand so that the rear wheel is on the ground.

7. Tighten the axle nut, brake caliper bolts and brake torque rod nut to the specified torques.

Tightening torques:

Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lbf)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29ft·lbf)

Brake torque rod nut:

23 Nm (2.3 m·kgf, 17ft·lbf)

EAU25870

Troubleshooting

Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.

The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

Use only genuine Yamaha replacement parts. Imitation parts may look like

Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

6

6-40



6

Troubleshooting charts

Starting problems or poor engine performance

WARNING

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

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

Check the compression.

There is no fuel.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

Check the ignition.

There is no compression.

Have a Yamaha dealer check the vehicle.

3. Ignition

Remove the spark plugs and check the electrodes.

Wet

Dry

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.


Check the battery.

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.



6-41

EAU25911

EWA10840



Engine overheating

●

●

EWA10400

WARNING

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is low.

Check the cooling system for leakage.

The coolant level is OK.

There is leakage.

Have a Yamaha dealer check and repair the cooling system.

There is no leakage.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a

Yamaha dealer check and repair the cooling system.

6

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

6-42


7

MOTORCYCLE CARE AND STORAGE

Care

EAU26010

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.

ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water.

Before cleaning

1. Cover the muffler outlet with a plastic bag after the engine has cooled down.

2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed.

3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod-

Cleaning

ECA10770

CAUTION:

●

●

●

Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray.

Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.

Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive

7-1

●

● cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.

Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.

For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield.

Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.



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.

ECA10790

CAUTION:

Do not use warm water since it increases the corrosive action of the salt.

2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.

After riding in the rain, near the sea or on salt-sprayed roads

Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads.

NOTE:

Salt sprayed on roads in the winter may remain well into spring.

1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.

After cleaning

1. Dry the motorcycle with a chamois or an absorbing cloth.

2. Immediately dry the drive chain and lubricate it to prevent it from rusting.

3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)

4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces.

7-2

5. Use spray oil as a universal cleaner to remove any remaining dirt.

6. Touch up minor paint damage caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry completely before storing or covering it.

EWA10930

WARNING

●

●

Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent.

Before operating the motorcycle test its braking performance and cornering behavior.

ECA10800

CAUTION:

● Apply spray oil and wax sparingly and make sure to wipe off any excess.

7


7


●

●

Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product.

Avoid using abrasive polishing compounds as they will wear away the paint.

NOTE:

Consult a Yamaha dealer for advice on what products to use.

Storage

EAU26160

Short-term

Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECA10810

CAUTION:

●

●

Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.

To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.

Long-term

Before storing your motorcycle for several months:

1. Follow all the instructions in the

“Care” section of this chapter.

2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to

“OFF”.

7-3

3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank.

4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

5. Perform the following steps to protect the cylinders, piston rings, etc.

from corrosion.

a. Remove the spark plug caps and spark plugs.

b. Pour a teaspoonful of engine oil into each spark plug bore.

c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps.



EWA10950

WARNING

To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand.

7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.

Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30

°C (90 °F)]. For more information on storing the battery, see page

6-33.

NOTE:

Make any necessary repairs before storing the motorcycle.

7

7-4


8

SPECIFICATIONS

Dimensions:

Overall length:

2125 mm (83.7 in)

Overall width:

765 mm (30.1 in)

Overall height:

1190 mm (46.9 in)

Seat height:

820 mm (32.3 in)

Wheelbase:

1450 mm (57.1 in)

Ground clearance:

140 mm (5.51 in)

Minimum turning radius:

2900 mm (114.2 in)

Weight:

With oil and fuel:

231.0 kg (509 lb) (U49)

232.0 kg (512 lb) (CAL)

Engine:

Engine type:

Liquid cooled 4-stroke, DOHC

Cylinder arrangement:

Forward inclined parallel 4-cylinder

Displacement:

998.0 cm³ (60.90 cu.in)

Bore

× stroke:

74.0

× 58.0 mm (2.91 × 2.28 in)

Compression ratio:

11.40 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0

°

10

° 30° 50° 70° 90° 110°

130

°F

YAMALUBE 4 (10W30) or SAE 10W30

YAMALUBE 4 (20W40) or SAE 20W40

–20

°

–10

° 0° 10° 20° 30° 40°

50

°C

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter cartridge replacement:

2.80 L (2.96 US qt) (2.46 Imp.qt)

With oil filter cartridge replacement:

3.00 L (3.17 US qt) (2.64 Imp.qt)

Cooling system:

Coolant reservoir capacity (up to the maximum level mark):

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

Radiator capacity (including all routes):

2.40 L (2.54 US qt) (2.11 Imp.qt)

Air filter:

Air filter element:

Dry element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

21.0 L (5.55 US gal) (4.62 Imp.gal)

Fuel reserve amount:

4.0 L (1.06 US gal) (0.88 Imp.gal)

8-1

Carburetor:

Manufacturer:

MIKUNI

Type x quantity:

BSR37 x 4

Spark plug(s):

Manufacturer/model:

NGK/CR9E

Manufacturer/model:

DENSO/U27ESR-N

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

68/43 (1.581)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

44/16 (2.750)

Transmission type:

Constant mesh 6-speed

Operation:

Left foot operation

Gear ratio:

1st:

35/14 (2.500)

2nd:

35/19 (1.842)


3rd:

30/20 (1.500)

4th:

28/21 (1.333)

5th:

30/25 (1.200)

6th:

29/26 (1.115)

Chassis:

Frame type:

Double cradle

Caster angle:

26.0 °

Trail:

104.0 mm (4.09 in)

Front tire:

Type:

Tubeless

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

BRIDGESTONE/BT020F U

Rear tire:

Type:

Tubeless

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

BRIDGESTONE/BT020R U

Loading:

Maximum load:

188 kg (415 lb) (CAL)

189 kg (417 lb) (U49)

(Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Loading condition:

0–90 kg (0–198 lb)

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

270 kPa (39 psi) (2.70 kgf/cm²)

Loading condition:

90–188 kg (198–415 lb) (CAL)

90–189 kg (198–417 lb) (U49)

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

Front wheel:

Wheel type:

Cast wheel

Rim size:

17M/C x MT3.50

Rear wheel:

Wheel type:

Cast wheel

Rim size:

17M/C x MT5.50

SPECIFICATIONS

Front brake:

Type:

Dual disc brake

Operation:

Right hand operation

Recommended fluid:

Dot 4

Rear brake:

Type:

Single disc brake

Operation:

Right foot operation

Recommended fluid:

Dot 4

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

140.0 mm (5.51 in)

Rear suspension:

Type:

Swingarm (link suspension)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

135.0 mm (5.31 in)

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

A.C. magneto

8

8-2


8

SPECIFICATIONS

Battery:

Model:

GT14B-4

Voltage, capacity:

12 V, 12.0 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 60 W/55.0 W

× 2

Tail/brake light:

12 V, 5 W/21.0 W

× 2

Front turn signal/position light:

12 V, 27 W/8.0 W

× 2

Rear turn signal light:

12 V, 27.0 W

× 2

Meter lighting:

12 V, 2.0 W

× 3

Neutral indicator light:

14 V, 1.4 W

× 1

High beam indicator light:

14 V, 1.4 W

× 1

Oil level warning light:

14 V, 1.4 W

× 1

Turn signal indicator light:

14 V, 1.4 W

× 2

Fuel level warning light:

12 V, 2.0 W

× 1

Coolant temperature indicator light:

LED

Fuses:

Main fuse:

30.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

20.0 A

Ignition fuse:

20.0 A

Radiator fan fuse:

10.0 A

Backup fuse:

10.0 A

8-3


EAU26351

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.

KEY IDENTIFICATION NUMBER:

Key identification number

VEHICLE IDENTIFICATION

NUMBER:

MODEL LABEL INFORMATION:

CONSUMER INFORMATION

EAU26380

Vehicle identification number

EAU26400

1. Key identification number

The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key.

1. Vehicle identification number

The vehicle identification number is stamped into the steering head pipe.

Record this number in the space provided.

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.

9

9-1



EAU26480

Model label

9

1. Model label

The model label is affixed to the frame

under the seat. (See page 3-10.)

Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

9-2



EAU26550

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,

U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.

area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

9

9-3

9



EAU26560

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

• Muffler

• Exhaust pipe

• Silencer

Intake system

• Air cleaner case

• Air cleaner element

• Intake duct

9-4



EAU26631

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.

Date of service

Mileage

Servicing dealer name and address

Remarks

Maintenance interval

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

24000 mi

(37000 km) or

36 months

28000 mi

(43000 km) or

42 months

32000 mi

(49000 km) or

48 months

9-5

9

9



Maintenance interval

36000 mi

(55000 km) or

54 months

40000 mi

(61000 km) or

60 months

Date of service

Mileage

Servicing dealer name and address

Remarks

9-6



YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED

EAU26661

WARRANTY

9

9-7

9



9-8



EAU26750

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor

Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period.

Y.E.S. is designed and administered by the same

Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to

“moving parts” or the “drive train” like many other plans.

And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be.

You don’t have to pay anything for covered repairs.

There’s no deductible to pay, and repairs aren’t

“pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs.

In addition, Travel and Recreation Interruption Protection

(TRIP) is included at no extra cost. TRIP gives you up to

$150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire

Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable!

This excellent Y.E.S. plan coverage is only available to

Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha

Extended Service.

9

9-9

9



We urge you to act now. You’ll get the excellent benefits of

TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your

Yamaha Limited Warranty expires.

A special note:

If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing

P.O. Box 6555

Cypress, CA 90630

1-(866)-YES-EXTD (1-866-937-3983)

9-10


A

B

Accessories and replacement parts ..... 6-23

Air filter element, cleaning .................... 6-17

C

Battery .................................................. 6-33

Brake and clutch levers, checking

and lubricating .................................... 6-30

Brake and shift pedals, checking

and lubricating .................................... 6-30

Brake fluid, changing ............................ 6-27

Brake fluid level, checking .................... 6-26

Brake lever ............................................. 3-7

Brake pedal ............................................ 3-7

Brake pedal position, adjusting............. 6-24

Cables, checking and lubricating .......... 6-29

Canister (for California only)................. 6-11

Carburetors, adjustment ....................... 6-19

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

Centerstand and sidestand,

checking and lubricating..................... 6-31

Clutch lever............................................. 3-6

Clutch lever free play, adjusting ........... 6-24

Coolant ................................................. 6-14

Coolant temperature warning light.......... 3-2

D

E

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

Drive chain, lubricating ......................... 6-29

Drive chain slack .................................. 6-27

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

Engine oil and oil filter cartridge ........... 6-12

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

Engine stop switch.................................. 3-6

F

EXUP system ........................................3-15

I

Front and rear brake pads,

checking..............................................6-25

Front fork, adjusting ..............................3-11

Front fork, checking...............................6-31

Fuel .........................................................3-8

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

Fuel level warning light............................3-2

Fuel tank cap...........................................3-8

Fuses, replacing ....................................6-34

H

Handlebar switches .................................3-5

Headlight bulb, replacing.......................6-35

Helmet holder........................................3-10

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

Horn switch .............................................3-6

K

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

L

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

Ignition circuit cut-off system .................3-16

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

M

Labels, location of ...................................1-5

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

Maintenance and lubrication,

periodic .................................................6-5

Maintenance, emission control

system...................................................6-3

Maintenance, periodic .............................6-1

Maintenance record ................................9-5

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

INDEX

N

O

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

P

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

Noise regulation ...................................... 9-4

Panels, removing and installing .............. 6-9

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

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

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

R

S

Rear brake light switch, adjusting ......... 6-25

Rear suspension, lubricating ................ 6-31

Safety defects, reporting......................... 9-3

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

Seat ...................................................... 3-10

Self-diagnosis devices ............................ 3-4

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

Shift pedal ............................................... 3-7

Shock absorber assembly,

adjusting ............................................. 3-13

Sidestand.............................................. 3-15

Spark plugs, checking........................... 6-10

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

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

Starter (choke) lever ............................... 3-9

Starting and warming up a cold

engine................................................... 5-1

Start switch ............................................. 3-6

Steering, checking ................................ 6-32

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

Storage compartment ........................... 3-11


INDEX

T

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

Tail/brake light bulb, replacing .............. 6-36

Throttle cable free play, adjusting ......... 6-19

Throttle grip and cable, checking

and lubricating .................................... 6-30

Tires ...................................................... 6-20

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

Troubleshooting .................................... 6-40

Troubleshooting charts ......................... 6-41

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

Turn signal light bulb, replacing ............ 6-37

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

V

Valve clearance, adjusting .................... 6-20

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

W

Warranty, extended................................. 9-9

Warranty, limited ..................................... 9-7

Wheel bearings, checking..................... 6-33

Wheel (front) ......................................... 6-37

Wheel (rear) .......................................... 6-38

Wheels .................................................. 6-23


PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2003.06-0.8

×1 CR

(E)

LIT-11626-17-40


FZS1000S

FZS1000SC

5LV-28199-13

No results