null  null
OWNER’S MANUAL
YZF600RS
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2003.04-0.7×1 CR
(E)
LIT-11626-17-16
5AH-28199-17
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
EAU10041
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
INTRODUCTION
EAU10080
Congratulations on your purchase of the Yamaha YZF600R. 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.
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
IMPORTANT MANUAL INFORMATION
EAU10130
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10010
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
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.
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
IMPORTANT MANUAL INFORMATION
EAU10191
AFFIX DEALER
LABEL HERE
YZF600RS
OWNER’S MANUAL
©2003 by Yamaha Motor Corporation,
U.S.A.
1st edition, March 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-11626-17-16
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1
Location of important labels ............1-5
Sidestand ..................................... 3-14
Ignition circuit cut-off system ........ 3-15
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
PRE-OPERATION CHECKS ............. 4-1
Pre-operation check list .................. 4-2
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Speedometer unit ...........................3-3
Tachometer ....................................3-3
Self-diagnosis device ......................3-3
Coolant temperature gauge ............3-4
Handlebar switches ........................3-4
Clutch lever .....................................3-5
Shift pedal .......................................3-6
Brake lever .....................................3-6
Brake pedal ....................................3-6
Fuel tank cap ..................................3-7
Fuel .................................................3-7
Starter (choke) lever .......................3-8
Seat ................................................3-9
Helmet holder .................................3-9
Storage compartment ...................3-10
Adjusting the front fork ..................3-10
Adjusting the shock absorber
assembly ...................................3-12
Luggage strap holders ..................3-14
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 .......................... 6-4
Removing and installing
cowlings ...................................... 6-8
Checking the spark plugs ............. 6-10
Engine oil and oil filter cartridge ... 6-11
Coolant ......................................... 6-14
Cleaning the air filter element ...... 6-17
Checking the air vent hose ........... 6-19
Air intake duct .............................. 6-19
Adjusting the carburetors ............. 6-20
Adjusting the throttle cable
free play .................................... 6-20
Adjusting the valve clearance ...... 6-20
Tires ............................................. 6-21
Cast wheels ................................. 6-23
Accessories and replacement
parts ......................................... 6-23
Adjusting the clutch lever free
play ........................................... 6-24
Adjusting the brake pedal
position ..................................... 6-25
Adjusting the rear brake light
switch ....................................... 6-25
Checking the front and rear
brake pads ................................ 6-26
Checking the brake fluid level ...... 6-26
Changing the brake fluid .............. 6-27
Drive chain slack .......................... 6-28
Lubricating the drive chain ........... 6-29
Checking and lubricating the
cables ....................................... 6-30
Checking and lubricating the
throttle grip and cable ............... 6-30
Checking and lubricating the
brake and shift pedals .............. 6-30
Checking and lubricating the
brake and clutch levers ............ 6-31
Checking and lubricating the
sidestand .................................. 6-31
Lubricating the rear suspension ... 6-31
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
TABLE OF CONTENTS
Checking the front fork .................6-32
Checking the steering ...................6-32
Checking the wheel bearings .......6-33
Battery ..........................................6-33
Replacing the fuses ......................6-34
Replacing the headlight bulb ........6-35
Replacing the tail/brake light
bulb ...........................................6-37
Replacing a turn signal light
bulb ...........................................6-37
Supporting the motorcycle ............6-37
Front wheel ...................................6-38
Rear wheel ...................................6-40
Troubleshooting ............................6-42
Troubleshooting charts .................6-43
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
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
EAU10270
1
MOTORCYCLES
ARE
SINGLE
TRACK VEHICLES. THEIR SAFE USE
AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
● OBSERVE THE WARNINGS AND
MAINTENANCE
REQUIREMENTS IN THE OWNER’S MANUAL.
● OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
●
Safe riding
● Always
make
pre-operation
checks. Careful checks may help
prevent an accident.
● This motorcycle is designed to carry the operator and a passenger.
● The failure of motorists to detect
and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching
and
passing
through intersections, since 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
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
●
●
due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).
• Always obey the speed limit and
never travel faster than warranted by road and traffic conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator footrests during operation to maintain control of the motorcycle.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
• Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
●
This motorcycle is designed for onroad use only. It is not suitable for
off-road use.
●
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
1-2
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stability and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding accessories to your motorcycle:
1
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
1
Loading
The total weight of the operator, passenger, accessories and cargo must
not exceed the maximum load limit of
182.0 kg (401 lb). 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.
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMABLE:
• Always turn the engine off when
refueling.
• Take care not to spill any gasoline on the engine or exhaust
system when refueling.
• Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has adequate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcycle, note the following:
• The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
●
●
• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
• Do not park the motorcycle near
a flammable source, (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
When transporting the motorcycle
in another vehicle, make sure that
it is kept upright. If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.
1-4
1
5AH17.book Page 5 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
EAU10381
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
1-5
5AH17.book Page 6 Tuesday, April 8, 2003 11:35 AM
SAFETY INFORMATION
1
1
4
CAUTION
Cleaning with alkaline or
acid cleaner, gasoline or
solvent will damage
windshield.
Use neutral detergent.
5JW-2835Y-00
2
5
3
6
1-6
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
DESCRIPTION
EAU10410
Left view
2
8. Grab bar
9. Shift pedal (page 3-6)
10.Radiator (page 6-14)
1.
2.
3.
4.
Air intake duct (page 6-19)
Fuel tank (page 3-7)
Shock absorber assembly spring preload adjusting ring (page 3-12)
Shock absorber assembly rebound damping force adjusting knob
(page 3-12)
5. Shock absorber assembly compression damping force adjusting screw
(page 3-12)
6. Storage compartment (page 3-10)
7. Helmet holder (page 3-9)
2-1
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
DESCRIPTION
EAU10420
Right view
2
1.
2.
3.
4.
5.
6.
7.
8.
9. Brake pedal (page 3-6)
10.Engine oil filler cap (page 6-11)
Luggage strap holder (page 3-14)
Rear brake fluid reservoir (page 6-26)
Coolant reservoir (page 6-14)
Front fork spring preload adjusting bolt (page 3-10)
Front fork rebound damping force adjusting screw (page 3-10)
Radiator cap (page 6-14)
Front fork compression damping force adjusting screw (page 3-10)
Engine oil level check window (page 6-11)
2-2
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
DESCRIPTION
EAU10430
Controls and instruments
2
1.
2.
3.
4.
5.
6.
7.
8.
9. Throttle grip (page 6-20)
10.Main switch/steering lock (page 3-1)
Clutch lever (page 3-5)
Left handlebar switches (page 3-4)
Starter (choke) lever (page 3-8)
Speedometer unit (page 3-3)
Tachometer (page 3-3)
Coolant temperature gauge (page 3-4)
Right handlebar switches (page 3-4)
Brake lever (page 3-6)
2-3
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU10460
Main switch/steering lock
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be removed.
To unlock the steering
To lock the steering
3
1. Push.
2. Turn.
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10510
ON
All electrical systems are supplied with
power, and the headlight, meter lighting, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
EAU10660
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING
1. Push.
2. Turn.
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
OFF
All electrical systems are off. The key
can be removed.
3-1
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped before turning the key to “OFF” or
“LOCK”.
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU11000
Indicator and warning lights
EAU11080
EAU11320
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
3.1 L (0.82 us.gal) (0.68 imp.gal). When
this occurs, refuel as soon as possible.
The electrical circuit of the warning light
can be checked according to the following procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on, have a
Yamaha dealer check the electrical circuit.
EAU11140
3
1.
2.
3.
4.
5.
Neutral indicator light “
”
Oil level warning light “
”
Fuel level warning light “ ”
Turn signal indicator light “
High beam indicator light “
”
”
EAU11020
Turn signal indicator light “
”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
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 according to the following procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on while
pushing the start switch, have a
Yamaha dealer check the electrical circuit.
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.
3-2
NOTE:
This model is equipped with a self-diagnosis device for the fuel level warning
light circuit. (See page 3-3.)
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU11630
Speedometer unit
EAU11851
Tachometer
EAU11981
Self-diagnosis device
This model is equipped with a self-diagnosis device for the following electrical
circuits:
● throttle position sensor
● fuel level warning light
If any of those circuits are defective, the
tachometer will repeatedly display the
following error code:
1. Odometer
2. Tripmeter reset knob
3. Tripmeter
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will enable you to plan future fuel stops.
0 r/min for
3 seconds
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
ECA10031
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 13200 r/min and above
Circuit-specific
number of r/min
for 2.5 seconds
(See the table
below.)
Current
engine
speed for
3 seconds
Use the table below to identify the faulty
electrical circuit.
Specific r/min for the faulty circuit
Throttle position sensor:
3000 r/min
Fuel level warning light:
8000 r/min
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.
3-3
3
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
ECA10040
CAUTION:
EAU12171
Coolant temperature gauge
When the tachometer displays an error code, the vehicle should be
checked as soon as possible in order to avoid engine damage.
EAU12341
Handlebar switches
Left
3
1. Coolant temperature gauge
2. Coolant temperature gauge red zone
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. The
coolant temperature varies with changes in the weather and engine load. If
the needle reaches or enters the red
zone, stop the vehicle and let the engine cool. (See page 6-43.)
1. Dimmer switch “
/
”
2. Turn signal switch “
/
”
3. Horn switch “
”
Right
ECA10020
CAUTION:
Do not operate the engine if it is
overheated.
1. Engine stop switch “
2. Start switch “ ”
3-4
/
”
5AH17.book Page 5 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU12400
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
ECA10050
EAU12820
Clutch lever
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
EAU12460
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When released, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
3
1. Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition circuit cut-off system. (See page
3-15.)
EAU12500
Horn switch “
”
Press this switch to sound the horn.
EAU12660
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12710
Start switch “ ”
Push this switch to crank the engine
with the starter.
3-5
5AH17.book Page 6 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU12870
Shift pedal
EAU12930
Brake lever
EAU12941
Brake pedal
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
3
1. Shift pedal
1. Brake pedal
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 6-speed constant-mesh transmission equipped on
this motorcycle.
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1.
2.
3.
4.
Arrow mark
Brake lever position adjusting dial
Brake lever
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.
3-6
5AH17.book Page 7 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13070
Fuel tank cap
EAU13210
NOTE:
The fuel tank cap cannot be closed unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
Fuel
EWA11090
WARNING
3
Make sure that the fuel tank cap is
properly closed before riding.
1. Fuel tank cap lock cover
2. Unlock.
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
To open the fuel tank cap
Open the fuel tank cap lock cover, insert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be
opened.
EWA10880
WARNING
●
To close the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.
●
3-7
Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot engine.
5AH17.book Page 8 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
ECA10070
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
EAU13300
3
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
19.0 L (5.02 us.gal) (4.18 imp.gal)
Fuel reserve amount:
3.1 L (0.82 us.gal) (0.68 imp.gal)
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
ECA11400
CAUTION:
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
EAU13610
Starter (choke) lever “
1. Starter (choke) lever “
”
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction (a) to turn on
the starter (choke).
Move the lever in direction (b) to turn off
the starter (choke).
ECA10990
CAUTION:
Do not use the starter (choke) for
more than 3 minutes as the exhaust
pipe may discolor from excessive
heat. In addition, extended use of
the starter (choke) will cause afterburning. If this occurs, turn off the
starter (choke).
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
3-8
5AH17.book Page 9 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13920
EAU14290
Seat
Helmet holder
To remove the seat
1. Insert the key into the helmet holder lock, and then turn it as shown.
3
1. Seat holder
2. Projection
2. Push the rear of the seat down to
lock it in place.
3. Remove the key.
1. Unlock.
2. Pull the seat off.
NOTE:
Make sure that the seat is properly secured before riding.
To install the seat
1. Insert the projections 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.
3-9
5AH17.book Page 10 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU14450
Storage compartment
When washing the vehicle, be careful
not to let any water enter the storage
compartment.
EAU14741
Adjusting the front fork
This front fork is equipped with spring
preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting
screws.
EWA10180
WARNING
3
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
1. Storage compartment
The storage compartment is located
under the seat. (See page 3-9.)
Spring preload
EWA10960
WARNING
●
●
Do not exceed the load limit of 3
kg (7 lb) for the storage compartment.
Do not exceed the maximum
load of 182.0 kg (401 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.
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 pre3-10
5AH17.book Page 11 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
load
and
thereby
soften
the
suspension, turn the adjusting bolt on
each fork leg in direction (b).
Rebound damping force
Compression damping force
NOTE:
Align the appropriate groove on the adjusting mechanism with the top of the
front fork cap bolt.
3
1. Current setting
2. Front fork cap bolt
Spring preload setting:
Minimum (soft):
8
Standard:
5
Maximum (hard):
1
1. Rebound damping force adjusting screw
1. Compression damping force adjusting screw
To increase the rebound damping force
and thereby harden the rebound damping, turn the adjusting screw on each
fork leg in direction (a). To decrease the
rebound damping force and thereby
soften the rebound damping, turn the
adjusting screw on each fork leg in direction (b).
To increase the compression damping
force and thereby harden the compression damping, turn the adjusting screw
on each fork leg in direction (a). To decrease the compression damping force
and thereby soften the compression
damping, turn the adjusting screw on
each fork leg in direction (b).
Rebound damping setting:
Minimum (soft):
10 click(s) in direction (b)*
Standard:
7 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
3-11
Compression damping setting:
Minimum (soft):
10 click(s) in direction (b)*
Standard:
7 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
5AH17.book Page 12 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
ECA10100
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
3
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
EAU15011
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.
ECA11220
CAUTION:
Never attempt to turn the spring preload and rebound damping force adjusting mechanisms beyond the
maximum or minimum settings.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To decrease the spring preload and thereby
soften the suspension, turn the adjusting ring in direction (b).
NOTE:
● Align the appropriate notch in the
adjusting ring with the position indicator on the shock absorber.
● Use the special wrench included in
the owner’s tool kit to make the adjustment.
Spring preload setting:
Minimum (soft):
1
Standard:
3
Maximum (hard):
7
Spring preload
1. Spring preload adjusting ring
2. Position indicator
3-12
5AH17.book Page 13 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
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):
25 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
3 click(s) in direction (b)*
* With the adjusting knob fully turned
in direction (a)
NOTE:
Although the total number of clicks of
the rebound 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 the rebound
damping force adjusting mechanism
and to modify the specifications as necessary.
Compression damping force
1. Compression damping force adjusting screw
2. Position indicator
3-13
To harden the compression damping,
decrease the setting by turning the adjusting screw. To soften the compression damping, increase the setting by
turning the adjusting screw. Make sure
that the position indicator is aligned
with the appropriate setting.
3
Compression damping setting:
Minimum (soft):
6
Standard:
4
Maximum (hard):
1
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.
5AH17.book Page 14 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
●
●
3
●
Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
Always have a Yamaha dealer
service the shock absorber.
EAU15230
Luggage strap holders
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.
1. Luggage strap holder
There are four luggage strap holders,
two of which can be turned out for easier access.
3-14
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
5AH17.book Page 15 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
below and have a Yamaha dealer repair it if it does not function properly.
EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is
still down.
● It cuts the running engine when the
transmission is in gear and the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system before riding.
3-15
3
5AH17.book Page 16 Tuesday, April 8, 2003 11:35 AM
INSTRUMENT AND CONTROL FUNCTIONS
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
NOTE:
This check is most reliable if performed with
a warmed-up engine.
3
YES
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
3-16
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
4
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
PRE-OPERATION CHECKS
EAU15601
Pre-operation check list
ITEM
4
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-7
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
6-11
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-14
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-26, 6-26
Rear brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-25, 6-26, 6-26
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
6-24
4-2
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
PRE-OPERATION CHECKS
ITEM
CHECKS
PAGE
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
Drive chain
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
Wheels and tires
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-30
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-31
Sidestand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-31
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
3-14
Air intake duct
• Check that the screen is not clogged.
• Clean if necessary.
6-19
6-20, 6-30
6-30
6-28, 6-29
4-3
4
6-21, 6-23
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING
●
●
5
●
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
EAU16130
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 3-15.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical circuit.
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8.)
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.
ECA10230
ECA10220
CAUTION:
CAUTION:
If the fuel level warning light comes
on, check the fuel level, and, if necessary, refuel as soon as possible.
5-1
●
The oil level warning light and
fuel level warning light should
come on when the start switch
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
OPERATION AND IMPORTANT RIDING POINTS
●
●
is pushed, and they should go
off when the start switch is released.
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 the warning light
does not come on when pushing the start switch, or if it does
not go off after starting with sufficient engine oil, have a
Yamaha dealer check the electrical circuit.
If the fuel level warning light remains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel as
soon as possible, and then
check the warning light again. If
the warning light does not come
on when pushing the start
switch, or if it does not go off af-
ter starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
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
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 35 seconds with the starter
5-2
5
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU16640
Starting a warm engine
EAU16671
Shifting
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
5
ECA10260
CAUTION:
●
1. Shift pedal
2. Neutral position
●
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the illustration.
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16680
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
5-3
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
OPERATION AND IMPORTANT RIDING POINTS
4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
NOTE:
Always shift gears at the recommended
shift points.
EAU16700
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
25 km/h (15.5 mi/h). If the engine is
about to stall or runs very roughly,
pull the clutch lever in and use the
brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
EAU16740
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
Shift up points:
1st → 2nd: 16 km/h (10 mi/h)
2nd → 3rd: 24 km/h (15 mi/h)
3rd → 4th: 32 km/h (20 mi/h)
4th → 5th: 40 km/h (25 mi/h)
5th → 6th: 48 km/h (30 mi/h)
Shift down points:
6th → 5th: 25 km/h (15.5 mi/h)
5th → 4th: 25 km/h (15.5 mi/h)
4th → 3rd: 25 km/h (15.5 mi/h)
3rd → 2nd: 25 km/h (15.5 mi/h)
2nd → 1st: 25 km/h (15.5 mi/h)
5-4
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
EAU17091
0–1000 km (0–600 mi)
Avoid prolonged operation above 6500
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 8000
r/min.
5
5AH17.book Page 5 Tuesday, April 8, 2003 11:35 AM
OPERATION AND IMPORTANT RIDING POINTS
ECA10301
EAU17200
CAUTION:
Parking
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element replaced.
When parking, stop the engine, and
then remove the key from the main
switch.
1600 km (1000 mi) and beyond
The vehicle can now be operated normally.
EWA10310
WARNING
●
ECA10310
CAUTION:
●
5
●
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
●
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
5-5
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17230
EAU17300
PERIODIC MAINTENANCE
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair of
the emission control devices and systems may be performed by any repair
establishment or individual that is certified (if applicable).
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOWING
PERIODIC
MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.
EAU17510
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-9.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
6-1
6
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10340
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
6
6-2
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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
12000 mi
16000 mi
20000 mi
(13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
12 months 18 months 24 months 30 months
1 *
Fuel line
• Check fuel hose for cracks or
damage.
• Replace if necessary.
2 *
Fuel filter
• Replace.
3
Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace every 8000 mi (13000
km) or 12 months.
4 *
Valve clearance
• Check and adjust valve clearance
when engine is cold.
5 *
Crankcase breather
system
• Check breather hose for cracks or
damage.
• Replace if necessary.
6 *
Carburetor synchronization
• Adjust synchronization of carburetors.
√
√
√
√
√
√
7 *
Idle speed
• Check and adjust engine idle
speed.
√
√
√
√
√
√
8 *
Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
√
√
√
√
√
√
√
√
√
√
Replace.
√
Replace.
√
Replace.
√
Every 26600 mi (42000 km)
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-3
6
√
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU32181
General maintenance and lubrication chart
INITIAL
No.
ITEM
ROUTINE
600 mi
(1000 km)
or
1 month
ODOMETER READINGS
4000 mi
(7000 km)
or
6 months
8000 mi
12000 mi
16000 mi
20000 mi
(13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
12 months 18 months 24 months 30 months
1 *
Air filter element
• Clean with solvent. (See NOTE.)
• Replace if necessary.
2 *
Clutch
• Check operation.
• Adjust or replace cable.
3 *
Front brake
4 *
Rear brake
5 *
Brake hoses
6 *
Wheels
• Check runout and for damage.
• Replace if necessary.
√
√
7 *
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√
8 *
Wheel bearings
• Check bearings for smooth operation.
• Replace if necessary.
√
6
√
√
√
√
√
√
√
√
√
√
√
• Check operation, fluid level, and
for fluid leakage. (See NOTE.)
• Replace brake pads if necessary.
√
√
√
√
√
√
• Check operation, fluid level, and
for fluid leakage. (See NOTE.)
• Replace brake pads if necessary.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Check for cracks or damage.
• Replace. (See NOTE.)
Every 4 years
6-4
5AH17.book Page 5 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
ROUTINE
Swingarm pivot
bearings
• Check bearing assemblies for
looseness.
• Moderately repack with lithiumsoap-based grease.
Drive chain
• Check chain slack/alignment and
condition.
• Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.
11 *
Steering bearings
• Check bearing assembly for
looseness.
• Moderately repack with lithiumsoap-based grease every 16000
mi (25000 km) or 24 months.
12 *
Chassis fasteners
13
9 *
10
600 mi
(1000 km)
or
1 month
ODOMETER READINGS
4000 mi
(7000 km)
or
6 months
8000 mi
12000 mi
16000 mi
20000 mi
(13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
12 months 18 months 24 months 30 months
√
Repack.
Every 600 mi (1000 km) or after washing the motorcycle riding in the rain
√
√
√
√
Repack.
√
• Check all chassis fitting and fasteners.
• Correct if necessary.
√
√
√
√
√
Brake and clutch lever pivot shafts
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
√
√
√
√
√
14
Brake and shift pedal pivot shafts
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
√
√
√
√
√
15
Sidestand pivot
• Check operation.
• Apply lithium-soap-based grease
(all-purpose grease) lightly.
√
√
√
√
√
16 *
Sidestand switch
• Check operation and replace if
necessary.
√
√
√
√
√
√
6-5
6
5AH17.book Page 6 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
6
ITEM
ROUTINE
600 mi
(1000 km)
or
1 month
ODOMETER READINGS
4000 mi
(7000 km)
or
6 months
8000 mi
12000 mi
16000 mi
20000 mi
(13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
12 months 18 months 24 months 30 months
17 *
Front fork
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
√
√
18 *
Shock absorber assembly
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
√
√
19 *
Rear suspension
link pivots
• Apply lithium-soap-based grease
lightly.
20
Engine oil
• Change (warm engine before
draining).
√
21 *
Engine oil filter cartridge
• Replace.
√
22 *
Cooling system
√
• Check hoses for cracks or damage.
• Replace if necessary.
√
√
√
√
√
√
24 *
Control and meter
cables
• Apply Yamaha chain and cable
lube or engine oil 10W-30 thoroughly.
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.
√
√
√
• Change with ethylene glycol antifreeze coolant every 24 months.
23 *
√
√
√
Change.
√
√
√
√
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-6
5AH17.book Page 7 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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
6-7
5AH17.book Page 8 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18780
Removing and installing
cowlings
The cowlings shown above need to be
removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time a cowling needs to be removed and installed.
EAU18911
Cowlings A and C
To remove one of the cowlings
1. Remove the bolts.
1. Bolt
1. Cowling A
2. Cowling B
6
1. Bolt
1. Bolt
2. Disconnect the turn signal light
lead connectors (and, for the leftside cowling, also the auxiliary
light lead coupler), and then take
the cowling off.
1. Cowling C
2. Cowling D
6-8
5AH17.book Page 9 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the grab bar by removing
the bolts.
3. Remove the screw, and then pull
the cowling off as shown.
1. Auxiliary light lead coupler (left side)
2. Turn signal light lead connector
1. Screw
To install the cowling
1. Connect the turn signal light lead
connectors (and, for the left-side
cowling, also the auxiliary light
lead coupler).
2. Place the cowling in the original
position, and then install the bolts.
EAU19050
NOTE:
Pull the cowling up, then back to remove it.
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the seat.
Cowling B
EAU19020
To remove the cowling
1. Remove the seat. (See page 3-9.)
2. Remove the screws, and then pull
the cowling off as shown.
Cowling D
To remove the cowling
1. Remove the seat and cowling B.
(See pages 3-9 and 6-8.)
6-9
1. Bolt
2. Screw
To install the cowling
1. Place the cowling in the original
position, and then install the
screw.
2. Install the grab bar by installing the
bolts.
3. Install the cowling and the seat.
6
5AH17.book Page 10 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19542
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.
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
1. Spark plug wrench
To remove a spark plug
1. Remove the spark plug cap.
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
NGK/CR9E or
DENSO/U27ESR-N
6
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
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.
6-10
5AH17.book Page 11 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU19911
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
4. Install the spark plug cap.
1. Spark plug gap
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.
To check the engine oil level
1. Place the vehicle on a level surface and hold it in an upright position.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
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.
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.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
6-11
6
5AH17.book Page 12 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The engine oil should be between the
minimum and maximum level marks.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
1. Engine oil drain bolt
6
NOTE:
Skip steps 5–7 if the oil filter cartridge is
not being replaced.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Remove the oil filter cartridge with
an oil filter wrench.
1. Engine oil filler cap
To change the engine oil (with or
without oil filter cartridge replacement)
1. Remove cowling A. (See page
6-8.)
1. Oil filter cartridge
2. Oil filter wrench
6-12
5AH17.book Page 13 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA11620
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
6. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
CAUTION:
●
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:
Check the washer for damage and replace it if necessary.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
1. O-ring
NOTE:
Make sure that the O-ring is properly
seated.
7. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
9. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replacement:
2.60 L (2.75 us.qt) (2.29 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 us.qt) (2.55 Imp.qt)
6-13
●
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.
10. 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.
6
5AH17.book Page 14 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10400
Coolant
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealer
check the vehicle.
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.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling.
6
EAU20070
CAUTION:
EAU20141
To check the coolant level
1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the vehicle is positioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Remove the seat. (See page 3-9.)
3. Check the coolant level in the coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
6-14
1. Maximum level mark
2. Minimum level mark
4. If the coolant is at or below the
minimum level mark, open the
coolant reservoir cap.
5. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then install the seat.
Coolant reservoir capacity (up to the
maximum level mark):
0.55 L (0.58 us.qt) (0.48 Imp.qt)
5AH17.book Page 15 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see page
6-43 for further instructions.
EAU20411
To change the coolant
1. Place the vehicle on a level surface and let the engine cool if necessary.
2. Remove the seat. (See page 3-9.)
3. Remove cowlings A, C and D.
(See page 6-8.)
4. Remove the fuel tank bolts, and
then lift the fuel tank. (Do not remove the fuel hoses.)
Never attempt to remove the radiator
cap when the engine is hot.
5. Remove the right air intake duct by
loosening the clamp screws.
6
EWA10410
WARNING
EWA10380
WARNING
1. Fuel tank bolt
●
●
Make sure that the fuel tank is
well supported.
Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
6-15
1. Clamp screw
2. Right air intake duct
6. Remove the radiator cap.
5AH17.book Page 16 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
12. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
13. Install the coolant reservoir by installing the screws.
14. Install the water pump drain bolt
and cylinder drain bolts, and then
tighten them to the specified
torques.
EWA10380
WARNING
Never attempt to remove the radiator
cap when the engine is hot.
1. Water pump drain bolt
2. Cylinder drain bolt
10. Remove the coolant reservoir by
removing the screws.
1. Radiator cap
6
Tightening torques:
Water pump drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder drain bolt:
7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)
15. Pour the specified amount of recommended coolant into the reservoir to the maximum level mark,
and then install the coolant reservoir cap.
16. Pour the recommended coolant
into the radiator until it is full, and
then install the radiator cap.
7. Place a container under the engine
to collect the used coolant.
8. Remove the water pump drain bolt
to drain the cooling system.
9. Remove the cylinder drain bolts to
drain the cooling system.
1. Screw
2. Coolant reservoir
11. Remove the coolant reservoir cap,
and then turn the coolant reservoir
upside down to empty it.
6-16
chapter6 Page 17 Monday, April 14, 2003 1:44 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Antifreeze/water mixture ratio:
1:1
Recommended anti-freeze:
High-quality ethylene glycol antifreeze containing corrosion inhibitors
for aluminum engines
Coolant quantity:
Radiator capacity (including all
routes):
1.95 L (2.06 us.qt) (1.72 Imp.qt)
Coolant reservoir capacity (up to the
maximum level mark):
0.30 L (0.32 us.qt) (0.26 Imp.qt)
ECA11010
CAUTION:
Hard water or salt water is harmful to
the engine. You may use soft water if
you can’t get distilled water.
19. 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.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
21. Install the right air intake duct, and
then tighten the clamp screws.
22. Place the fuel tank in the original
position, and then install the bolts.
23. Install the cowlings.
24. Install the seat.
17. Start the engine, let it idle for several minutes, and then turn it off.
18. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radiator, and then install the radiator
cap.
EAU20931
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 3-9.)
2. Remove the fuel tank bolts.
6
1. Fuel tank bolt
3. Lift the fuel tank to position it away
from the air filter case. (Do not disconnect the fuel hoses!)
EWA10410
WARNING
●
6-17
Make sure that the fuel tank is
well supported.
5AH17.book Page 18 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
●
Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
NOTE:
The sponge material should be wet but
not dripping.
4. Remove the air filter case cover by
removing the screws and bolt.
Recommended oil:
Yamaha foam air filter oil or other
quality air filter oil
8. Insert the air filter element into the
air filter case.
1. Air filter element
ECA10480
6. Clean the air filter element with solvent, and then squeeze the remaining solvent out.
6
CAUTION:
●
●
1. Air filter case cover
2. Screw
3. Bolt
5. Pull the air filter element out.
7. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
6-18
Make sure that the air filter element is properly seated in the
air filter case.
The engine should never be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
9. Install the air filter case cover by installing the screws and bolt.
10. Place the fuel tank in the original
position, and then install the bolts.
5AH17.book Page 19 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10420
●
●
EAU21200
EAU21210
WARNING
Checking the air vent hose
Air intake duct
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.
1. Air vent hose
1. Air intake duct
Periodically check the air vent hose for
dust or water that may be deposited in
the hose. If dust or water is found, remove the air vent hose, thoroughly
clean it, and then install it.
Check that the screen of the intake duct
is not blocked. Clean the screen if necessary.
11. Install the seat.
ECA10540
CAUTION:
Do not operate the motorcycle with
the air vent hose removed.
6-19
6
5AH17.book Page 20 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21270
Adjusting the carburetors
The carburetors are important parts of
the engine and emission control system, which require very sophisticated
adjustment. Therefore, all carburetor
adjustments should be left to a Yamaha
dealer, who has the necessary professional knowledge and experience.
EAU21380
Adjusting the throttle cable
free play
1. Throttle cable free play
6
The throttle cable free play should measure 3.0–7.0 mm (0.12–0.28 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6-20
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.
5AH17.book Page 21 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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):
0.0–90.0 kg (0–198 lb):
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
90.0–182.0 kg (198–401 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
Maximum load*:
182.0 kg (401 lb)
* Total weight of rider, passenger, cargo and accessories
evenly from side to side. Properly
adjust the suspension for your load,
and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure
that the total weight of the cargo, rider, passenger, and accessories
(cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the
vehicle. Operation of an overloaded
vehicle could cause tire damage, an
accident, or even injury.
Tire inspection
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 heaviest items close to the center of the
vehicle, and distribute the weight
6-21
1. Tire sidewall
2. Tire wear indicator
3. Tire tread depth
6
5AH17.book Page 22 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
●
Tire information
●
Minimum tire tread depth (front and
rear):
1.0 mm (0.04 in)
EWA10580
WARNING
●
6
●
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.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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.
6-22
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:
120/60 ZR17M/C (55W)
Manufacturer/model:
BRIDGESTONE/BT57F
DUNLOP/D204FG
MICHELIN/MACADAM 90X
METZELER/MEZ1
Rear tire:
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
BRIDGESTONE/BT57R
DUNLOP/D204G
MICHELIN/MACADAM 90X
METZELER/MEZ1
FRONT and REAR:
Tire air valve:
TR412
Valve core:
#9000A (original)
5AH17.book Page 23 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10600
WARNING
This motorcycle is fitted with superhigh-speed tires. Note the following
points in order to make the most efficient use of these tires.
● Use only the specified replacement tires. Other tires may run
the danger of bursting at super
high speeds.
● Brand-new tires can have a relatively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is advisable before doing any highspeed 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.
EAU21960
Cast wheels
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage before each ride. If any damage is
found, have a Yamaha dealer replace the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
6-23
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
6
5AH17.book Page 24 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
any consequences caused by the
use of items which have not been
approved by Yamaha.
EAU22020
Adjusting the clutch lever free
play
1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
6
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.
1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
3. Tighten the locknut.
6-24
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.
5AH17.book Page 25 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22240
Adjusting the brake pedal
position
the braking performance, which may
result in loss of control and an accident.
1. Distance between brake pedal and footrest
EAU22270
Adjusting the rear brake light
switch
1. Rear brake light switch
2. Rear brake light switch adjusting nut
The top of the brake pedal should be
positioned approximately 42.0 mm
(1.65 in) below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, have a
Yamaha dealer adjust it.
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).
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
6-25
6
5AH17.book Page 26 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22311
Checking the front and rear
brake pads
Front brake
1. Brake pad wear indicator
6
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the position of the wear indicator
while applying the brake. If a brake pad
has worn to the point that the wear indicator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level
Front brake
1. Minimum level mark
Rear brake
Rear brake
1. Minimum level mark
1. Brake pad wear indicator
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
6-26
5AH17.book Page 27 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
●
●
●
Be careful that water does not enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid:
DOT 4
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
6-27
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.
6
5AH17.book Page 28 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22760
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same position for proper wheel alignment.
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright position.
6
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
20.0–30.0 mm (0.79–1.18 in)
1. Drive chain slack
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22930
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loosen the drive chain, turn the adjusting nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
6-28
1.
2.
3.
4.
Axle nut
Alignment marks
Drive chain slack adjusting nut
Locknut
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.
5AH17.book Page 29 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
Tightening torque:
Axle nut:
117 Nm (11.7 m·kgf, 85 ft·lbf)
EAU23020
ECA11110
Lubricating the drive chain
CAUTION:
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
Do not use engine oil or any other lubricants for the drive chain, as they
may contain substances that could
damage the O-rings.
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.
6-29
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23090
EAU23110
Checking and lubricating the
throttle grip and cable
Checking and lubricating the
brake and shift pedals
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)
EWA10710
6
EAU23131
Checking and lubricating the
cables
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.
6-30
5AH17.book Page 31 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23140
EAU23200
EAU23250
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
Lubricating the rear
suspension
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
EWA10730
WARNING
Recommended lubricant:
Lithium-soap-based grease
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-purpose grease)
6-31
6
5AH17.book Page 32 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23270
EAU23280
Checking the front fork
Checking the steering
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
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.
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.
6
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.
ECA10590
CAUTION:
EWA10750
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
6-32
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.
5AH17.book Page 33 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23290
EAU23370
Checking the wheel bearings
Battery
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.
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
●
6-33
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.
6
5AH17.book Page 34 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
●
●
6
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
EAU23621
Replacing the fuses
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.
1.
2.
3.
4.
5.
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Spare fuse
1. Main fuse
6-34
5AH17.book Page 35 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
The main fuse and the fuse box, which
contains the fuses for the individual circuits, are located under the seat. (See
page 3-9.)
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.
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.
Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
15.0 A
Radiator fan fuse:
7.5 A
Ignition fuse:
7.5 A
EAU23740
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.
6
1. Headlight coupler
2. Headlight bulb cover
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
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.
6-35
5AH17.book Page 36 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
●
1. Headlight bulb holder
EWA10790
WARNING
6
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
●
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transparency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or thinner.
Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of a
wattage higher than specified.
3. 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:
1. Do not touch the glass part of the bulb.
6-36
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
5AH17.book Page 37 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24130
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
1. Screw
EAU24200
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
screws.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
ECA10680
ECA11190
CAUTION:
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
Do not overtighten the screw, otherwise the lens may break.
6-37
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand upright. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
6
5AH17.book Page 38 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU24611
To remove the front wheel
EWA10820
2. Remove the front fender by removing the screws.
3. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
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. Disconnect the speedometer cable from the front wheel.
1.
2.
3.
4.
5.
6.
7.
6
1.
2.
3.
4.
5.
6.
Speedometer cable
Screw
Front fender
Bolt
Brake caliper
Brake hose holder
6-38
Front fender
Screw
Front wheel axle pinch bolt
Wheel axle
Bolt
Brake caliper
Brake hose holder
4. Lift the front wheel off the ground
according to the procedure on
page 6-37.
5. Remove the brake hose holders
on each side by removing the bolt
and nut.
5AH17.book Page 39 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
7. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
6. Remove the brake calipers on
each side by removing the bolts.
7. Pull the wheel axle out, remove the
speedometer gear unit, and then
remove the wheel.
ECA11050
CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
EAU24851
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the projections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:
Make sure that the slot in the speedometer gear unit fits over the retainer on
the fork leg.
1. Speedometer gear unit
2. Slot
3. Speedometer gear unit retainer
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Install the brake calipers by installing the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake calipers onto the brake
discs.
6. Install the brake hose holders by
installing the bolts and nuts.
6-39
Tightening torques:
Wheel axle:
65 Nm (6.5 m·kgf, 47 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
8. Install the front fender by installing
the screws.
9. Connect the speedometer cable.
10. Push down hard on the handlebar
several times to check for proper
fork operation.
6
5AH17.book Page 40 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25080
Rear wheel
EAU25222
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 wheel axle nut and the
brake caliper bolts.
1. Bolt
2. Right wheel axle guide
2. Remove the cotter pin, and then
loosen the brake torque rod nut at
the brake caliper bracket.
6
3. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
4. Remove the axle nut and the left
wheel axle guide, and then remove the brake caliper by removing the bolts.
5. Disconnect the brake torque rod
from the brake caliper bracket by
removing the nut and the bolt.
6. Loosen the locknut and the drive
chain slack adjusting nut on both
sides of the swingarm.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
1.
2.
3.
4.
5.
Axle nut
Left wheel axle guide
Locknut
Drive chain slack adjusting nut
Wheel axle
1.
2.
3.
4.
8. Pull the wheel axle out along with
the right wheel axle guide, remove
the brake caliper bracket, and then
remove the wheel.
Cotter pin
Nut
Bolt
Brake torque rod
6-40
5AH17.book Page 41 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torques:
Axle nut:
117 Nm (11.7 m·kgf, 85 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
Brake torque rod nut:
30 Nm (3.0 m·kgf, 21 ft·lbf)
6. Install a new cotter pin into the
brake torque rod bolt.
EWA11280
1. Brake caliper bracket
ECA11070
CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU25651
To install the rear wheel
1. Install the wheel, right wheel axle
guide, and caliper bracket by inserting the wheel axle from the
right-hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-28.)
3. Install the left wheel axle guide and
the axle nut, and then lower the
rear wheel so that it is on the
ground.
4. Install the brake caliper by installing the bolts, and then connect the
brake torque rod to the brake caliper bracket by installing the bolt
and nut.
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake caliper onto the brake
disc.
5. Tighten the axle nut, the brake caliper bolts and the brake torque rod
nut to the specified torques.
6-41
WARNING
Always use a new cotter pin for the
brake torque rod bolt.
6
5AH17.book Page 42 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25870
Troubleshooting
6
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
6-42
5AH17.book Page 43 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25911
Troubleshooting charts
Starting problems or poor engine performance
EWA10840
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
6
Operate the electric starter.
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-43
The engine does not start.
Have a Yamaha dealer
check the vehicle.
5AH17.book Page 44 Tuesday, April 8, 2003 11:35 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EWA10400
WARNING
●
●
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
The coolant level is low.
Check the cooling system
for leakage.
6
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
6-44
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
MOTORCYCLE CARE AND STORAGE
ucts onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and degreaser off with water.
EAU26010
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a motorcycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
●
Cleaning
ECA10770
CAUTION:
●
●
●
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
7-1
●
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing
compound
after
washing.
7
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
MOTORCYCLE CARE AND STORAGE
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
7
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold water and a mild detergent, after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
7-2
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA10930
WARNING
●
●
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
Before operating the motorcycle test its braking performance and cornering behavior.
ECA10800
CAUTION:
●
Apply spray oil and wax sparingly and make sure to wipe off
any excess.
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
MOTORCYCLE CARE AND STORAGE
●
●
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
EAU26160
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
CAUTION:
●
●
Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
7-3
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
7
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
MOTORCYCLE CARE AND STORAGE
EWA10950
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
7
°C (90 °F)]. For more information
on storing the battery, see page
6-33.
NOTE:
Make any necessary repairs before
storing the motorcycle.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less
than 0 °C (30 °F) or more than 30
7-4
chapter8 Page 1 Monday, April 14, 2003 1:44 PM
SPECIFICATIONS
Dimensions:
Overall length:
2060 mm (81.1 in)
Overall width:
725 mm (28.5 in)
Overall height:
1190 mm (46.9 in)
Seat height:
805 mm (31.7 in)
Wheelbase:
1415 mm (55.7 in)
Ground clearance:
135 mm (5.3 in)
Minimum turning radius:
3200 mm (126.0 in)
Weight:
With oil and fuel:
212.0 kg (467 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward inclined parallel 4-cylinder
Displacement:
599.0 cm³ (36.55 cu.in)
Bore × stroke:
62.0 × 49.6 mm (2.44 × 1.95 in)
Compression ratio:
12.00 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:
Type:
YAMALUBE 4, SAE10W30 or SAE20W40
Fuel tank capacity:
19.0 L (5.02 us.gal) (4.18 imp.gal)
Fuel reserve amount:
3.1 L (0.82 us.gal) (0.68 imp.gal)
Carburetor:
0°
10°
30° 50° 70° 90° 110° 130°F
YAMALUBE 4 (10W30)
or SAE 10W30
YAMALUBE 4 (20W40)
or SAE 20W40
–20° –10°
0°
10° 20° 30° 40° 50°C
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
2.60 L (2.75 us.qt) (2.29 Imp.qt)
With oil filter cartridge replacement:
2.90 L (3.07 us.qt) (2.55 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):
1.95 L (2.06 us.qt) (1.72 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Unleaded gasoline only
8-1
Manufacturer:
KEIHIN
Type x quantity:
CVKD36 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:
82/48 (1.708)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
47/15 (3.133)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
8
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
SPECIFICATIONS
Gear ratio:
1st:
37/13 (2.846)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
28/21 (1.333)
5th:
25/21 (1.190)
6th:
29/27 (1.074)
Chassis:
Frame type:
Diamond
Caster angle:
25.0 °
Trail:
97.0 mm (3.82 in)
Front tire:
8
Type:
Tubeless
Size:
120/60 ZR17M/C (55W)
Size:
120/60 ZR17 (55W)
Manufacturer/model:
BRIDGESTONE/BT57F
Manufacturer/model:
DUNLOP/D204FG
Manufacturer/model:
MICHELIN/MACADAM 90X
Manufacturer/model:
METZELER/MEZ1
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Size:
160/60 ZR17 (69W)
Manufacturer/model:
BRIDGESTONE/BT57R
Manufacturer/model:
DUNLOP/D204G
Manufacturer/model:
MICHELIN/MACADAM 90X
Manufacturer/model:
METZELER/MEZ1
Loading:
Maximum load:
182.0 kg (401 lb)
(Total weight of rider, passenger, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0.0–90.0 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Loading condition:
90.0–182.0 kg (198–401 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
8-2
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
Front wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT3.50
Rim size:
17 x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Rim size:
17 x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
Dot 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
SPECIFICATIONS
Recommended fluid:
Dot 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
130.0 mm (5.12 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
120.0 mm (4.72 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
YTX12-BS
Voltage, capacity:
12 V, 10.0 Ah
Headlight:
Front turn signal/position light:
12 V, 27.0 W/8.0 W × 2
Rear turn signal light:
12 V, 27.0 W × 2
Meter lighting:
12 V, 1.7 W × 4
Neutral indicator light:
12 V, 3.4 W × 1
High beam indicator light:
12 V, 3.4 W × 1
Oil level warning light:
12 V, 3.4 W × 1
Turn signal indicator light:
12 V, 3.4 W × 1
Fuel level warning light:
12 V, 3.4 W × 1
Fuses:
Main fuse:
30.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
15.0 A
Ignition fuse:
7.5 A
Radiator fan fuse:
7.5 A
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60.0 W/55.0 W × 1
Tail/brake light:
12 V, 8.0 W/27.0 W × 1
8-3
8
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26351
Identification numbers
EAU26380
EAU26400
Key identification number
Vehicle identification number
1. Key identification number
1. Vehicle identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
9
9-1
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in your
area.
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26480
Model label
1. Model label
The model label is affixed to the frame
under the seat. (See page 3-9.) Record
the information on this label in the
space provided. This information will be
needed when ordering spare parts from
a Yamaha dealer.
9
9-2
5AH17.book Page 3 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26550
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.
9
9-3
5AH17.book Page 4 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26560
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system
• Muffler
• Exhaust pipe
• Silencer
Intake system
• Air cleaner case
• Air cleaner element
• Intake duct
9
9-4
5AH17.book Page 5 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
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.
Maintenance
interval
9
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1000 km) or
1 month
4000 mi
(7000 km) or
6 months
8000 mi
(13000 km) or
12 months
12000 mi
(19000 km) or
18 months
16000 mi
(25000 km) or
24 months
20000 mi
(31000 km) or
30 months
24000 mi
(37000 km) or
36 months
28000 mi
(43000 km) or
42 months
32000 mi
(49000 km) or
48 months
9-5
Remarks
5AH17.book Page 6 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
Remarks
36000 mi
(55000 km) or
54 months
40000 mi
(61000 km) or
60 months
9
9-6
5AH17.book Page 7 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26661
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED
WARRANTY
9
9-7
5AH17.book Page 8 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
9
9-8
5AH17.book Page 9 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
EAU26750
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.
Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factory-backed coverage for extra
peace of mind.
Y.E.S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, 36 months or, on certain
models, even 48 months beyond your warranty period.
Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comforting uninterrupted factorybacked protection can be.
Y.E.S. coverage is transferable to a new owner if you
sell or trade-in. That can make your Yamaha much more
valuable!
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.
You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.
9
9-9
5AH17.book Page 10 Tuesday, April 8, 2003 11:35 AM
CONSUMER INFORMATION
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primary ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)
9
9-10
5AH17.book Page 1 Tuesday, April 8, 2003 11:35 AM
INDEX
A
F
Accessories and replacement parts...... 6-23
Air filter element, cleaning..................... 6-17
Air intake duct ....................................... 6-19
Air vent hose, checking......................... 6-19
B
Battery................................................... 6-33
Brake and clutch levers, checking
and lubricating ................................... 6-31
Brake and shift pedals, checking
and lubricating .................................... 6-30
Brake fluid, changing ............................ 6-27
Brake fluid level, checking .................... 6-26
Brake lever.............................................. 3-6
Brake pedal............................................. 3-6
Brake pedal position, adjusting ............. 6-25
H
D
Dimmer switch ........................................ 3-5
Drive chain, lubricating.......................... 6-29
Drive chain slack................................... 6-28
E
Engine break-in....................................... 5-4
Engine oil and oil filter cartridge............ 6-11
Engine, starting a warm .......................... 5-3
Engine stop switch .................................. 3-5
Oil level warning light .............................. 3-2
P
Parking ....................................................5-5
Part locations .......................................... 2-1
Pre-operation check list...........................4-2
R
Rear brake light switch, adjusting ......... 6-25
Rear suspension, lubricating................. 6-31
S
Handlebar switches ................................ 3-4
Headlight bulb, replacing ...................... 6-35
Helmet holder ......................................... 3-9
High beam indicator light ........................ 3-2
Horn switch............................................. 3-5
Safety defects, reporting .........................9-3
Safety information ...................................1-1
Seat......................................................... 3-9
Self-diagnosis device .............................. 3-3
Shifting ....................................................5-3
Shift pedal ............................................... 3-6
Shock absorber assembly, adjusting ....3-12
Sidestand ..............................................3-14
Sidestand, checking and lubricating......6-31
Spark plugs, checking ...........................6-10
Specifications .......................................... 8-1
Speedometer unit.................................... 3-3
Starter (choke) lever................................ 3-8
Starting and warming up a cold
engine ................................................... 5-1
Start switch..............................................3-5
Steering, checking.................................6-32
Storage....................................................7-3
Storage compartment............................ 3-10
Supporting the motorcycle .................... 6-37
I
C
Cables, checking and lubricating .......... 6-30
Carburetors, adjustment ....................... 6-20
Care ........................................................ 7-1
Clutch lever ............................................. 3-5
Clutch lever free play, adjusting............ 6-24
Coolant.................................................. 6-14
Coolant temperature gauge .................... 3-4
Cowlings, removing and installing........... 6-8
O
Front and rear brake pads,
checking ............................................. 6-26
Front fork, adjusting.............................. 3-10
Front fork, checking .............................. 6-32
Fuel......................................................... 3-7
Fuel level warning light ........................... 3-2
Fuel tank cap .......................................... 3-7
Fuses, replacing ................................... 6-34
Identification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Indicator and warning lights.................... 3-2
K
Key identification number ....................... 9-1
L
Labels, location of................................... 1-5
Luggage strap holders.......................... 3-14
M
Main switch/steering lock........................ 3-1
Maintenance and lubrication, periodic .... 6-4
Maintenance, emission control system... 6-3
Maintenance, periodic ............................ 6-1
Maintenance record................................ 9-5
Model label ............................................. 9-2
N
Neutral indicator light.............................. 3-2
Noise regulation...................................... 9-4
T
Tachometer ............................................. 3-3
Tail/brake light bulb, replacing ..............6-37
Throttle cable free play, adjusting ......... 6-20
5AH17.book Page 2 Tuesday, April 8, 2003 11:35 AM
INDEX
Throttle grip and cable, checking
and lubricating ................................... 6-30
Tires...................................................... 6-21
Tool kit .................................................... 6-1
Troubleshooting.................................... 6-42
Troubleshooting charts ......................... 6-43
Turn signal indicator light........................ 3-2
Turn signal light bulb, replacing............ 6-37
Turn signal switch................................... 3-5
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) ......................................... 6-38
Wheel (rear).......................................... 6-40
Wheels.................................................. 6-23
OWNER’S MANUAL
YZF600RS
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2003.04-0.7×1 CR
(E)
LIT-11626-17-16
5AH-28199-17
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