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Manuals and User Guides for Yamaha YZF-R1. We have 16 Yamaha YZF-R1 manuals available for free PDF download: Service Manual, Owner’s Manual, Parts Catalog, Manual, Kit Manual, Assembly Instructions Manual, Assembly Instructions

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PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2003.12-5.3

×

1 CR

(E)

LIT-11626-17-55

OWNER’S MANUAL

YZF-R1S(C)

5VY-28199-10

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

EAU10041

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

INTRODUCTION

EAU10080

Congratulations on your purchase of the Yamaha YZF-R1(C). 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.

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 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

CAUTION:

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

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

NOTE:

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

NOTE:

●

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

● is subsequently sold.

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

EWA10010

WARNING

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

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

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

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

IMPORTANT MANUAL INFORMATION

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

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

THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.

U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

YZF-R1S(C)

OWNER’S MANUAL

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

1st edition, December 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-11626-17-55

EAU10192

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SAFETY INFORMATION

………………1-1

Location of important labels ………..1-5

DESCRIPTION

…………………………….2-1

Left view ……………………………………2-1

Right view ………………………………….2-2

Controls and instruments …………….2-3

INSTRUMENT AND CONTROL

FUNCTIONS

…………………………………3-1

Main switch/steering lock …………….3-1

Indicator and warning lights …………3-2

Multi-function meter unit ……………..3-5

Handlebar switches ………………….3-10

Clutch lever …………………………….3-11

Shift pedal ………………………………3-12

Brake lever ……………………………..3-12

Brake pedal …………………………….3-13

Fuel tank cap …………………………..3-13

Fuel ……………………………………….3-14

Catalytic converter ……………………3-15

Seats ……………………………………..3-15

Helmet holders ………………………..3-16

Adjusting the front fork ……………..3-17

Adjusting the shock absorber assembly ……………………………..3-18

Luggage strap holders ………………3-21

EXUP system ………………………….3-21

Sidestand ……………………………….3-21

Ignition circuit cut-off system ……..3-22

PRE-OPERATION CHECKS

…………. 4-1

Pre-operation check list …………….. 4-2

OPERATION AND IMPORTANT

RIDING POINTS

………………………….. 5-1

Starting the engine ……………………. 5-1

Shifting ……………………………………. 5-2

Engine break-in ………………………… 5-3

Parking ……………………………………. 5-4

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 the cowling and panels ………………… 6-8

Checking the spark plugs ………… 6-10

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

Engine oil and oil filter cartridge … 6-11

Coolant …………………………………. 6-14

Replacing the air filter element …. 6-16

Adjusting the throttle cable free play ……………………………………. 6-18

Adjusting the valve clearance …… 6-18

Tires ……………………………………… 6-19

Cast wheels …………………………… 6-21

TABLE OF CONTENTS

Adjusting the clutch lever free play ……………………………………. 6-22

Adjusting the rear brake light switch …………………………………. 6-22

Checking the front and rear brake pads …………………………………… 6-23

Checking the brake fluid level …… 6-23

Changing the brake fluid ………….. 6-24

Drive chain slack …………………….. 6-25

Lubricating the drive chain ……….. 6-26

Checking and lubricating the cables ………………………………… 6-27

Checking and lubricating the throttle grip and cable …………… 6-27

Checking and lubricating the brake and clutch levers …………. 6-27

Checking and lubricating the sidestand ……………………………. 6-28

Lubricating the swingarm pivots … 6-28

Checking the front fork …………….. 6-29

Checking the steering ……………… 6-29

Checking the wheel bearings ……. 6-30

Battery …………………………………… 6-30

Replacing the fuses …………………. 6-32

Replacing a headlight bulb ……….. 6-34

Tail/brake light ………………………… 6-37

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

Replacing the license plate light bulb ……………………………………. 6-37

Replacing an auxiliary light bulb … 6-38

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

TABLE OF CONTENTS

Supporting the motorcycle …………6-39

Front wheel ……………………………..6-40

Rear wheel ……………………………..6-42

Troubleshooting ……………………….6-43

Troubleshooting charts ……………..6-44

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

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

EAU10280

MOTORCYCLES ARE SINGLE

TRACK VEHICLES. THEIR SAFE

USE AND OPERATION ARE DEPEN-

DENT UPON THE USE OF PROPER

RIDING TECHNIQUES AS WELL AS

THE EXPERTISE OF THE OPERA-

TOR. EVERY OPERATOR SHOULD

KNOW THE FOLLOWING REQUIRE-

MENTS BEFORE RIDING THIS

MOTORCYCLE.

HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT

●

SOURCE ON ALL ASPECTS OF

MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS

AND MAINTENANCE REQUIRE-

●

●

MENTS IN THE OWNER’S MAN-

UAL.

OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING

TECHNIQUES.

OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED

BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-

SARY BY MECHANICAL CONDI-

TIONS.

Safe riding

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

● prevent an accident.

This motorcycle is designed to carry the operator and a passenger.

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

Many accidents have been caused by an automobile driver who did not see the motorcycle.

Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when you are approaching and passing through intersections, since in-

SAFETY INFORMATION

●

● tersections are the most likely places for motorcycle accidents to occur.

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

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

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

• Know your skills and limits.

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

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

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

1

1-1

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1

SAFETY INFORMATION

●

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

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

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

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

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

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

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

Never ride under the influence of alcohol or other drugs.

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

Protective apparel

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

●

●

Always wear an approved helmet.

Wear a face shield or goggles.

Wind in your unprotected eyes could contribute to an impairment

●

●

● of vision that could delay seeing a hazard.

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

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

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

They become very hot and can

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

A passenger should also observe the above precautions.

Modifications

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

Modifications may also make your motorcycle illegal to use.

Loading and accessories

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

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

1-2

U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM

Loading

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

201 kg (443 lb) (CAL) / 202 kg (445 lb)

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

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

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

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

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

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

Accessories

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

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

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

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

1-3

SAFETY INFORMATION

● 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.

1

U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM

1

SAFETY INFORMATION

Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

• Always turn the engine off when refueling.

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

• Never refuel while smoking or in

● the vicinity of an open flame.

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

● equate ventilation.

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

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

●

●

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

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

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

U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM

Location of important labels

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

SAFETY INFORMATION

EAU10381

1 2,3 4,5,6 7,8

1

1-5

10 9

U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM

SAFETY INFORMATION

1

1

CAUTION

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

Use neutral detergent.

5JW-00

5 California only

HOW TO LAYOUT FUEL HOSES

FUEL DELIVERY

FUEL TANK

2

3

4

PREMIUM UNLEADED GASOLINE ONLY

91 Min. Pump Octane (R+M) 2

5PW-2415E-10

California only

EMISSION HOSE ROUTING

FUEL TANK ATMOSPHERE

6

PRESS. REGULATOR

FUEL PUMP

(FUEL FILTER)

5VY-2178A-00

California only

THROTTLE BODY

CHARCOAL

CANISTER

5SL-21686-00

1-6

8

9

U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM

7

3JJ-28446-A1

10

SAFETY INFORMATION

1

290 kPa, {2.90 kgf/cm

2

}, 42psi

5VY-21668-00

1-7

2

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

DESCRIPTION

Left view

1. Fuse box (page 6-32)

2. Front fork compression damping force adjusting screw (page 3-17)

3. Front fork rebound damping force adjusting screw (page 3-17)

4. Front fork spring preload adjusting bolt (page 3-17)

5. Front brake fluid reservoir (page 6-23)

6. Shock absorber assembly spring preload adjusting ring (page 3-18)

7. Battery (page 6-30)

8. Electronic fuel injection fuse (page 6-32)

9. Main fuse (page 6-32)

10.Owner’s tool kit (page 6-1)

11.Engine oil drain bolt (page 6-11)

12.Engine oil filter cartridge (page 6-11)

2-1

EAU10410

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

Right view

DESCRIPTION

EAU10420

2

1. Luggage strap holder (page 3-21)

2. Helmet holder (page 3-16)

3. Passenger seat lock (page 3-15)

4. Rear brake fluid reservoir (page 6-23)

5. Shock absorber assembly compression damping force adjusting screw

(page 3-18)

6. Engine oil filler cap (page 6-11)

7. Air filter element (page 6-16)

8. Engine oil level check window (page 6-11)

2-2

9. Shock absorber assembly rebound damping force adjusting screw

(page 3-18)

10.Coolant reservoir (page 6-14)

2

U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM

DESCRIPTION

Controls and instruments

1. Clutch lever (page 3-11)

2. Left handlebar switches (page 3-10)

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

4. Multi-function meter unit (page 3-5)

5. Right handlebar switches (page 3-10)

6. Throttle grip (page 6-18)

7. Brake lever (page 3-12)

2-3

EAU10430

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

To lock the steering

Main switch/steering lock

EAU10460

NOTE:

The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls.

EAU10660

OFF

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

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

EAU10680

LOCK

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

EAU10600

ON

All electrical circuits are supplied with power, the meter lighting, taillight, license plate light, auxiliary lights and position lights come on, and the engine can be started. The key cannot be removed.

1. Push.

2. Turn.

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

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

3. Remove the key.

3

3-1

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

3

INSTRUMENT AND CONTROL FUNCTIONS

To unlock the steering

EAU11001

Indicator and warning lights

EAU11060

Neutral indicator light “ ”

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

High beam indicator light “ ”

EAU11080

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

1. Push.

2. Turn.

Push the key in, and then turn it to

“OFF” while still pushing it.

EWA10060

WARNING

Never turn the key to “OFF” or

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

“LOCK”.

1. Left turn signal indicator light “ ”

2. Neutral indicator light “ ”

3. High beam indicator light “ ”

4. Right turn signal indicator light “ ”

5. Fuel level warning light “ ”

6. Oil level warning light “ ”

7. Coolant temperature warning light “ ”

8. Shift timing indicator light

9. Engine trouble warning light “ ”

EAU11030

Turn signal indicator lights “ ” and

“ ”

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

EAU11250

Oil level warning light “ ”

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

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

“ON”.

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

Yamaha dealer check the electrical circuit.

NOTE:

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

3-2

U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

● This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5 seconds.

If this occurs, have a Yamaha dealer check the vehicle.

NOTE:

This model is also equipped with a selfdiagnosis device for the fuel level detection circuit. If the fuel level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The fuel level warning light will flash eight times, then go off for 2.5

seconds. If this occurs, have a Yamaha dealer check the vehicle.

ECA10020

CAUTION:

Do not operate the engine if it is overheated.

EAU11360

Fuel level warning light “ ”

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

3.4 L (0.90 US gal) (0.75 Imp.gal).

When this occurs, refuel as soon as possible.

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

“ON”.

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

Yamaha dealer check the electrical circuit.

EAU11422

Coolant temperature warning light

“ ”

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

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

“ON”.

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

Yamaha dealer check the electrical circuit.

3

3-3

3

U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

Coolant temperature

Display Conditions

Under 39 °C

(Under 103 °F)

What to do

Message “LO” is displayed.

OK. Go ahead with riding.

40–116 °C

(104–242 °F)

Temperature is displayed.

OK. Go ahead with riding.

117–139 °C

(243–283 °F)

Above 140 °C

(Above 284 °F)

Temperature display flashes.

Warning light comes on.

Stop the vehicle and allow it to idle until the coolant temperature goes down.

If the temperature does not go down,

stop the engine. (See page 6-44.)

Message “HI” flashes.

Warning light comes on.

Stop the engine and allow it to cool.

(See page 6-44.)

3-4

U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

EAU11530

Engine trouble warning light “ ”

This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-

diagnosis system. (See page 3-5 for an

explanation of the self-diagnosis device.)

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

“ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.

cuit. (See page 3-5 for a detailed expla-

nation of the function of this indicator light and on how to set it.)

Multi-function meter unit

EAU34550

EAU11571

Shift timing indicator light

This indicator light can be set to come on and go off at the desired engine speeds and is used to inform the rider when it is time to shift to the next higher gear.

The electrical circuit of the indicator light can be checked by turning the key to “ON”.

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

Yamaha dealer check the electrical cir-

1. Clock

2. Speedometer

3. “SELECT” button

4. “RESET” button

5. Tachometer

6. Coolant temperature display/air intake temperature display

7. Odometer/tripmeters/fuel reserve tripmeter/stopwatch

8. Shift timing indicator light

EWA12421

WARNING

Be sure to stop the vehicle before making any setting changes to the multi-function meter unit.

The multi-function meter unit is equipped with the following:

3

3-5

U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM

3

INSTRUMENT AND CONTROL FUNCTIONS

●

●

●

●

●

●

●

●

●

●

● a speedometer (which shows the riding speed) a tachometer (which shows engine speed) an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came on) a stopwatch a clock a coolant temperature display an air intake temperature display a self-diagnosis device a display brightness and shift timing indicator light control mode

NOTE:

● Be sure to turn the key to “ON” before using the “SELECT” and “RE-

SET” buttons.

● To switch the speedometer and odometer/tripmeter displays between kilometers and miles, press the “SELECT” button for at least one second.

Tachometer

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.

When the key is turned to “ON”, the tachometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit.

ECA10031

CAUTION:

Do not operate the engine in the tachometer red zone.

Red zone: 13750 r/min and above

Clock mode

1. Clock

2. Speedometer

Turn the key to “ON”.

To set the clock

1. Push the “SELECT” button and

“RESET” button together for at least two seconds.

2. When the hour digits start flashing, push the “RESET” button to set the hours.

3-6

U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM

3. Push the “SELECT” button, and the minute digits will start flashing.

4. Push the “RESET” button to set the minutes.

5. Push the “SELECT” button and then release it to start the clock.

Odometer, tripmeter, and stopwatch modes

1. Coolant temperature display/air intake temperature display

2. Odometer/tripmeters/fuel reserve tripmeter/stopwatch

3. Shift timing indicator light

Push the “SELECT” button to switch the display between the odometer mode “ODO”, the tripmeter modes

“TRIP A” and “TRIP B” and the stopwatch mode in the following order:

INSTRUMENT AND CONTROL FUNCTIONS

TRIP A

→

TRIP B

→

ODO

→

Stopwatch

→

TRIP A

If the fuel level warning light comes on

(see page 3-2), the odometer display

will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case, push the

“SELECT” button to switch the display between the various tripmeter, odometer, and stopwatch modes in the following order:

F-TRIP

→

Stopwatch

→

TRIP A

→

TRIP B

→

ODO

→

F-TRIP

To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi).

Stopwatch mode

2. Push the “SELECT” button to stop the stopwatch.

3. Push the “SELECT” button again to reset the stopwatch.

Split-time measurement

1. Push the “RESET” button to start the stopwatch.

2. Push the “RESET” button to measure split-times. (The colon “:” will start flashing.)

3. Push the “RESET” button to display the final split-time or push the

“SELECT” button to stop the stopwatch and display total elapsed time.

4. Push the “SELECT” button to reset the stopwatch.

Coolant temperature display

The coolant temperature display indicates the temperature of the coolant.

Push the “RESET” button to switch the coolant temperature display to the air intake temperature display.

Standard measurement

1. Push the “RESET” button to start the stopwatch.

3

3-7

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3

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

When the coolant temperature display is selected, “C” is displayed for one second, and then the coolant temperature is displayed.

ECA10020

CAUTION:

Do not operate the engine if it is overheated.

Air intake temperature display

The air intake temperature display indicates the temperature of the air drawn into the air filter case. Push the “RE-

SET” button to switch the coolant temperature display to the air intake temperature display.

NOTE:

●

Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes

● on when the engine overheats.

When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air intake temperature was displayed prior to turning the key to “OFF”.

● When the air intake temperature display is selected, “A” is displayed before the temperature.

Self-diagnosis devices

This model is equipped with a self-diagnosis device for various electrical circuits.

If any of those circuits are defective, the engine trouble warning light will come on, and then the right display will indicate a two-digit error code (e.g., 11, 12,

13).

If the right display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle.

ECA11590

CAUTION:

If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage.

3-8

Display brightness and shift timing indicator light control mode

This mode cycles through five control functions, allowing you to make the following settings in the order listed below.

● Display brightness:

This function allows you to adjust

● the brightness of the displays and tachometer to suit the outside lighting conditions.

Shift timing indicator light activity:

This function allows you to choose whether or not the indicator light should be activated and whether it should flash or stay on when acti-

●

● vated.

Shift timing indicator light activation:

This function allows you to select the engine speed at which the indicator light will be activated.

Shift timing indicator light deactivation:

This function allows you to select the engine speed at which the indicator light will be deactivated.

U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

● Shift timing indicator light brightness:

This function allows you to adjust the brightness of the indicator light to suit your preference.

NOTE:

● To make any settings in this mode, you have to cycle through all of its functions. However, if the key is turned to “OFF” or the engine is

● started before completing the procedure, only the settings made before the “SELECT” button was last pushed will be applied.

In this mode, the right display shows the current setting for each function (except the shift timing indicator light activity function).

To adjust the brightness of the multifunction meter displays and tachometer

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” button.

3. Turn the key to “ON”, and then release the “SELECT” button after five seconds.

4. Push the “RESET” button to select the desired brightness level.

5. Push the “SELECT” button to confirm the selected brightness level.

The control mode changes to the shift timing indicator light activity function.

To set the shift timing indicator light activity function

1. Push the “RESET” button to select one of the following indicator light activity settings:

● The indicator light will stay on when activated. (This setting is selected when the indicator light stays on.)

● The indicator light will flash when activated. (This setting is selected when the indicator light flashes four times per

● second.)

The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected when the indicator light flashes once every two seconds.)

2. Push the “SELECT” button to confirm the selected indicator light activity. The control mode changes to the shift timing indicator light activation function.

To set the shift timing indicator light activation function

NOTE:

The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/min. From 7000 r/min to

12000 r/min, the indicator light can be set in increments of 500 r/min. From

12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min.

1. Push the “RESET” button to select the desired engine speed for activating the indicator light.

2. Push the “SELECT” button to confirm the selected engine speed.

The control mode changes to the shift timing indicator light deactivation function.

3

3-9

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3

INSTRUMENT AND CONTROL FUNCTIONS

To set the shift timing indicator light deactivation function

NOTE:

● The shift timing indicator light deactivation function can be set between 7000 r/min and 15000 r/min.

From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From

12000 r/min to 15000 r/min, the indicator light can be set in incre-

● ments of 200 r/min.

Be sure to set the deactivation function to a higher engine speed than for the activation function, otherwise the shift timing indicator light will remain deactivated.

1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light.

2. Push the “SELECT” button to confirm the selected engine speed.

The control mode changes to the shift timing indicator light brightness function.

To adjust the shift timing indicator light brightness

1. Push the “RESET” button to select the desired indicator light brightness level.

2. Push the “SELECT” button to confirm the selected indicator light brightness level. The right display will return to the odometer or tripmeter mode.

Handlebar switches

Left

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “ ”

Right

1. Engine stop switch “ / ”

2. Start switch “ ”

3-10

EAU12343

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INSTRUMENT AND CONTROL FUNCTIONS

EAU12400

Dimmer switch “ / ”

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

ECA10050

CAUTION:

See page 5-1 for starting instruc-

tions prior to starting the engine.

EAU12460

Turn signal switch “ / ”

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

or when the throttle cable is stuck.

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ”

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

Clutch lever

EAU12820

1. Clutch lever

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

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

tion circuit cut-off system. (See page

3-22.)

EAU12710

Start switch “ ”

Push this switch to crank the engine with the starter.

3

3-11

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INSTRUMENT AND CONTROL FUNCTIONS

Shift pedal

EAU12870

Brake lever

EAU33850 it by aligning a groove on the adjusting knob with the “ ” mark on the brake lever.

3

1. Shift pedal

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

1. Brake lever

2. Brake lever position adjusting knob

3. Distance between brake lever and handlebar grip

4. “ ” mark

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

The brake lever is equipped with a position adjusting knob. To adjust the distance between the brake lever and the handlebar grip, turn the adjusting knob while holding the lever pushed away from the handlebar grip. When the desired position is obtained, be sure to set

3-12

U5VY10E0.book Page 13 Thursday, December 11, 2003 8:48 AM

Brake pedal

INSTRUMENT AND CONTROL FUNCTIONS

EAU12941

Fuel tank cap

EAU13070

NOTE:

The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.

EWA11090

WARNING

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

3

1. Brake pedal

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

1. Fuel tank cap lock cover

2. Unlock.

To open the fuel tank cap

Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened.

To close the fuel tank cap

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

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

3-13

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3

INSTRUMENT AND CONTROL FUNCTIONS

Fuel

EAU13210

1. Fuel tank filler tube

2. Fuel level

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

EWA10880

WARNING

●

●

Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands.

Avoid spilling fuel on the hot engine.

ECA10070

CAUTION:

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

EAU13380

Recommended fuel:

PREMIUM UNLEADED GASOLINE

ONLY

Fuel tank capacity:

18.0 L (4.76 US gal) (3.96 Imp.gal)

Fuel reserve amount (when the fuel level warning light comes on):

3.4 L (0.90 US gal) (0.75 Imp.gal)

ECA11400

CAUTION:

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

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

[(R+M)/2] of 91 or higher, or a research

3-14 octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. 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.

U5VY10E0.book Page 15 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

EAU13430

Catalytic converter

This model is equipped with a catalytic converter in the exhaust chamber.

EWA10860

WARNING

The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work.

ECA10700

CAUTION:

The following precautions must be observed to prevent a fire hazard or other damages.

●

Use only unleaded gasoline.

●

The use of leaded gasoline will cause unrepairable damage to the catalytic converter.

Never park the vehicle near pos-

●

sible fire hazards such as grass or other materials that easily burn.

Do not allow the engine to idle too long.

Seats

Rider seat

EAU33860

To remove the rider seat

Pull back the rear of the rider seat as shown, remove the bolts, and then pull the seat off.

1. Bolt

To install the rider seat

Insert the projection on the front of the rider seat into the seat holder as shown, place the seat in the original position, and then install the bolts.

1. Projection

2. Seat holder

Passenger seat

To remove the passenger seat

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

3

1. Passenger seat lock

2. Unlock.

3-15

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3

INSTRUMENT AND CONTROL FUNCTIONS

2. While holding the key in that position, lift the front of the passenger seat and pull it forward.

Helmet holders

EAU33870

To release a helmet from a helmet holder

Remove the passenger seat, remove the helmet from the helmet holder, and then install the seat.

To install the passenger seat

1. Insert the projection on the rear of the passenger seat into the seat holder as shown, and then push the front of the seat down to lock it in place.

1. Helmet holder

The helmet holders are located on the bottom of the passenger seat.

1. Projection

2. Seat holder

2. Remove the key.

NOTE:

Make sure that the seats are properly secured before riding.

To secure a helmet to a helmet holder

1. Remove the passenger seat. (See page 3-15.)

2. Attach the helmet to a helmet holder, and then securely install the passenger seat.

EWA11040

WARNING

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

3-16

U5VY10E0.book Page 17 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

Rebound damping force

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

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

load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b).

NOTE:

Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt.

Spring preload

1. Current setting

2. Front fork cap bolt

1. Rebound damping force adjusting screw

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

1. Spring preload adjusting bolt

To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each fork leg in direction (a). To decrease the spring pre-

Spring preload setting:

Minimum (soft):

8

Standard:

4.5

Maximum (hard):

0

Rebound damping setting:

Minimum (soft):

26 click(s) in direction (b)*

Standard:

10 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

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

3-17

3

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3

INSTRUMENT AND CONTROL FUNCTIONS

Compression damping force

ECA10100

CAUTION:

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

1. Compression damping force adjusting screw

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

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.

EAU33970

Adjusting the shock absorber assembly

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

ECA10100

CAUTION:

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

Spring preload

Compression damping setting:

Minimum (soft):

25 click(s) in direction (b)*

Standard:

10 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

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

1. Special wrench

2. Spring preload adjusting ring

3. Position indicator

3-18

U5VY10E0.book Page 19 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

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

NOTE:

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

● dicator on the shock absorber.

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

Spring preload setting:

Minimum (soft):

1

Standard:

4

Maximum (hard):

9

1. Quick fastener screw

2. Bolt

3. Cowling

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

1. Rebound damping force adjusting screw

Rebound damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:

17 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

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

3. Place the cowling in its original position, install and tighten the quick fastener screw, and then install the bolt.

Rebound damping force

Adjust the rebound damping force as follows.

1. Remove the bolt, loosen and remove the quick fastener screw, and then pull the cowling away from the motorcycle as shown.

3-19

3

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3

INSTRUMENT AND CONTROL FUNCTIONS

Compression damping force

1. Compression damping force adjusting screw

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

Compression damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:

12 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

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

NOTE:

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

EWA10220

WARNING

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

●

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

●

●

●

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.

3-20

U5VY10E0.book Page 21 Thursday, December 11, 2003 8:48 AM

INSTRUMENT AND CONTROL FUNCTIONS

Luggage strap holders

1. Luggage strap holder

2. Hook

There are four luggage strap holders on the bottom of the passenger seat. To use the strap holders, remove the passenger seat, unhook the straps from the hooks, and then install the seat with the straps hanging out from under the

passenger seat. (See page 3-15.)

EAU15181 EAU15280

EXUP system

This model is equipped with Yamaha’s

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

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

ECA10190

CAUTION:

●

●

The EXUP system has been set and extensively tested at the

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

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

EAU15300

Sidestand

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

NOTE:

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

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

EWA10240

WARNING

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

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

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

3

3-21

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3

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 side-

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

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

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

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

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

EWA10250

WARNING

If a malfunction is noted, have a

Yamaha dealer check the system before riding.

3-22

U5VY10E0.book Page 23 Thursday, December 11, 2003 8:48 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?

YES

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES

NO

NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK.

The motorcycle can be ridden.

NOTE:

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

The neutral switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

until checked by a Yamaha dealer.

3

3-23

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4

PRE-OPERATION CHECKS

EAU15591

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

NOTE:

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

EWA11150

WARNING

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

4-1

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

PRE-OPERATION CHECKS

EAU15602

Pre-operation check list

ITEM

Fuel

Engine oil

Coolant

Front brake

Rear brake

Clutch

CHECKS

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check coolant level in reservoir.

• If necessary, add recommended coolant to specified level.

• Check cooling system for leakage.

• Check operation.

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

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

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

• Check hydraulic system for leakage.

• 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.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

PAGE

3-14

6-11

6-14

6-23, 6-23

6-23, 6-23

6-22

4

4-2

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4

PRE-OPERATION CHECKS

Throttle grip

ITEM

Control cables

Drive chain

Wheels and tires

Shift pedal

Brake pedal

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch

CHECKS

• Make sure that operation is smooth.

• Check cable free play.

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

• Make sure that operation is smooth.

• Lubricate if necessary.

• Check chain slack.

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Correct if necessary.

• Make sure that operation is smooth.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

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

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

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

4-3

PAGE

6-18, 6-27

6-27

6-25, 6-26

6-19, 6-21

6-28

—

—

3-21

—

—

6-27

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

OPERATION AND IMPORTANT RIDING POINTS

EAU15950

●

●

●

EWA10270

WARNING

Become thoroughly familiar with all operating controls and their functions before riding.

Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.

Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.

Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

EAU16251

Starting the engine

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

● The transmission is in the neutral position.

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

EWA10290

WARNING

●

●

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

described on page 3-22.

Never ride with the sidestand down.

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

ECA11830

CAUTION:

The following warning lights and indicator light should come on for a few seconds, then go off.

●

●

Oil level warning light

Fuel level warning light

5-1

●

Coolant temperature warning light

●

●

Shift timing indicator light

Engine trouble warning light

If a warning or indicator light does

not go off, see page 3-2 for the corre-

sponding warning and indicator light circuit check.

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. Start the engine by pushing the start switch.

NOTE:

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

5

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

5

OPERATION AND IMPORTANT RIDING POINTS

ECA11130

CAUTION:

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

NOTE:

The engine is warm when it quickly responds to the throttle.

Shifting

EAU16671

CAUTION:

●

●

the transmission.

Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

ECA10260

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

1. Shift pedal

2. Neutral position

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

The gear positions are shown in the illustration.

NOTE:

To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage the clutch.

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

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

5-2

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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: 20 km/h (12.5 mi/h)

2nd

→

3rd: 30 km/h (18.8 mi/h)

3rd

→

4th: 40 km/h (25.0 mi/h)

4th

→

5th: 50 km/h (31.3 mi/h)

5th

→

6th: 60 km/h (37.5 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: —

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 7000 r/min.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 8000 r/min.

5

5-3

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5

OPERATION AND IMPORTANT RIDING POINTS

ECA10301

CAUTION:

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

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

ECA10310

CAUTION:

●

●

Keep the engine speed out of the tachometer red zone.

If any engine trouble should occur during the engine break-in period, immediately have a

Yamaha dealer check the vehicle.

EAU17211

Parking

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

EWA10310

WARNING

●

●

Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them.

Do not park on a slope or on soft ground, otherwise the vehicle may overturn.

ECA10380

CAUTION:

Never park in an area where there are fire hazards such as grass or other flammable materials.

5-4

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

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

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

EWA10320

WARNING

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

EAU17231 EAU17300

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR MOTORCYCLE IS IMPOR-

TANT IN ORDER TO ENJOY LONG,

PLEASURABLE SERVICE. ESPE-

CIALLY IMPORTANT ARE THE MAIN-

TENANCE SERVICES RELATED TO

EMISSIONS CONTROL. THESE

CONTROLS NOT ONLY FUNCTION

TO ENSURE CLEANER AIR, BUT

ARE ALSO VITAL TO PROPER EN-

GINE OPERATION AND MAXIMUM

PERFORMANCE. IN THE FOLLOW-

ING PERIODIC MAINTENANCE

CHARTS, THE SERVICES RELATED

TO EMISSIONS CONTROL ARE

GROUPED SEPARATELY. THESE

SERVICES REQUIRE SPECIALIZED

DATA, KNOWLEDGE, AND EQUIP-

MENT. YAMAHA DEALERS ARE

TRAINED AND EQUIPPED TO PER-

FORM THESE PARTICULAR SER-

VICES.

Owner’s tool kit

EAU34690

1. Owner’s tool kit

The owner’s tool kit is located under the

passenger seat. (See page 3-15.)

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

6-1

6

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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.

EWA12370

WARNING

Do not touch the muffler bracket until the exhaust system has cooled.

1. Muffler bracket

6-2

U5VY10E0.book Page 3 Thursday, December 11, 2003 8:48 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

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

1

2

3

4

5

*

*

*

*

*

Fuel line

Spark plugs

Valve clearance

Crankcase breather system

Electronic fuel injection

• Check fuel hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

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

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check and adjust engine idle speed and synchronization.

√

√

√

√

√

√

Replace.

√

√

Every 26600 mi (42000 km)

√

√

6

7

*

*

Exhaust system

Evaporative emission control system

(For California only)

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check control system for damage.

• Replace if necessary.

√ √

8

*

Air induction system

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

• Replace any damaged parts if necessary.

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

6-3

√

√

√

√

√

√

Replace.

√

√

√

√

√

√

√

√

√

√

6

U5VY10E0.book Page 4 Thursday, December 11, 2003 8:48 AM

6

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32182

General maintenance and lubrication chart

No.

1

*

Air filter element

2

*

Clutch

3

*

Front brake

4

*

Rear brake

5

*

Brake hoses

6

*

Wheels

7

*

Tires

ITEM

8

*

Wheel bearings

ROUTINE

• Check condition and damage.

• Replace if necessary.

• Check operation.

• Adjust or replace cable.

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

• Replace brake pads if necessary.

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

• Replace brake pads if necessary.

• Check for cracks or damage.

• Replace.

• Check runout and for damage.

• Replace if necessary.

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearings for smooth operation.

• Replace if necessary.

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

√ √ √ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Every 4 years

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

6-4

U5VY10E0.book Page 5 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

9

10

11

12

13

14

15

16

*

*

*

*

*

Swingarm pivot bearings

Drive chain

Steering bearings

Steering damper

Chassis fasteners

Brake and clutch lever pivot shafts

Sidestand pivot

Sidestand switch

• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease.

• Check chain slack/alignment and condition.

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

• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.

• Check operation and for oil leakage.

• Check all chassis fitting and fasteners.

• Correct if necessary.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Check operation.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Check operation and replace if necessary.

√

Repack.

Every 500 mi (800 km) and after washing the motorcycle or riding in the rain

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Repack.

√

√

√

√

√

√

√

√

√

√

√

6

6-5

U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM

6

PERIODIC MAINTENANCE AND MINOR REPAIR

No.

ITEM ROUTINE

17

18

19

20

*

*

*

Front fork

Shock absorber assembly

Rear suspension link pivots

Engine oil

21

*

Engine oil filter cartridge

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation.

• Correct if necessary.

• Change (warm engine before draining).

• Replace.

22

23

24

*

*

*

Cooling system

EXUP system

Control cables

• Check hoses for cracks or damage.

• Replace if necessary.

• Change with ethylene glycol antifreeze coolant every 24 months.

• Check operation, cable free play and pulley position.

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

INITIAL

600 mi

(1000 km) or

1 month

ODOMETER READINGS

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

√ √ √ √ √

√

√

√

√

√

√

√

√

√

√

√

√

√

Change.

Every 12000 mi (19000 km)

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

6-6

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PERIODIC MAINTENANCE AND MINOR REPAIR

No.

ITEM ROUTINE

INITIAL

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months

ODOMETER READINGS

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

25

*

Throttle grip housing and cable

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

√ √

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

√ √ √

NOTE:

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

EAU17650

6

NOTE:

●

●

Air filter

• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it.

• The air filter element needs to be replaced more frequently when 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.

6-7

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU18721

Removing and installing the cowling and panels

The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.

Cowling A

EAU33980

To remove the cowling

Remove the bolt, loosen and remove the quick fastener screws, slide the cowling backward, and then remove it.

1. Panel A

2. Panel B

6

1. Cowling A

1. Quick fastener screw

2. Bolt

3. Cowling A

1. Panel C

2. Panel D

6-8

U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Place the cowling in its original position, install and tighten the quick fastener screws, and then install the bolt.

1. Cowling A

To install the cowling

1. Insert the projections into the slots, and then slide the cowling forward.

EAU19292

Panels A and C

To remove one of the panels

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

EAU33990

Panels B and D

To remove one of the panels

1. Remove the rider seat. (See page

3-15.)

2. Remove the screw, and then remove the panel as shown.

6

1. Slot

2. Projection

1. Screw

2. Panel A

To install the panel

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

1. Screw

2. Panel B

6-9

U5VY10E0.book Page 10 Thursday, December 11, 2003 8:48 AM

6

PERIODIC MAINTENANCE AND MINOR REPAIR

To install the panel

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

2. Install the rider seat.

Checking the spark plugs

EAU19651

The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they 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.

The porcelain insulator around the center electrode of each spark plug should be a medium-to-light tan (the ideal color when the vehicle is ridden normally), and all spark plugs installed in the engine should have the same color. 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.

If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced.

Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification.

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9 ft·lbf)

Specified spark plug:

NGK/CR9EK

6-10

U5VY10E0.book Page 11 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

ECA10840

CAUTION:

Do not use any tools to remove or install the spark plug cap, otherwise the ignition coil coupler may get damaged. The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly. To remove the spark plug cap, simply twist it back and forth while pulling it out; to install it, twist it back and forth while pushing it in.

EAU19680

Canister (for California only)

EAU34002

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.

This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following:

●

●

Check each hose connection.

Check each hose and canister for

● cracks or damage. Replace if damaged.

Make sure that the canister breather is not blocked, and if necessary, clean it.

To check the engine oil level

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

NOTE:

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

A slight tilt to the side can result in an incorrect 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 in the bottom-right side of the crankcase.

6

6-11

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PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

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

b. Remove the engine oil filler cap with the special wrench as shown.

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 with the special wrench.

5. Remove the engine oil drain bolt to drain the oil from the crankcase.

6

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

4. Engine oil filler cap

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 as follows.

a. Fit the rubber protector on the special wrench.

NOTE:

The special wrench and rubber protector are included in the owner’s tool kit.

1. Engine oil filler cap

2. Special wrench

3. Rubber protector c. Add sufficient oil of the recommended type to raise it to the correct level.

d. Install the engine oil filler cap with the special wrench.

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

1. Remove cowling A. (See page

6-8.)

1. Engine oil drain bolt

NOTE:

Skip steps 6–8 if the oil filter cartridge is not being replaced.

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

6-12

U5VY10E0.book Page 13 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Oil filter wrench

2. Engine oil filter cartridge

1. O-ring

NOTE:

An oil filter wrench is available at a

Yamaha dealer.

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

NOTE:

Make sure that the O-ring is properly seated.

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

1. Torque wrench

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

9. 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.

6

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

6-13

U5VY10E0.book Page 14 Thursday, December 11, 2003 8:48 AM

6

PERIODIC MAINTENANCE AND MINOR REPAIR

10. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap with the special wrench.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge replacement:

2.90 L (3.07 US qt) (2.55 Imp.qt)

With oil filter cartridge replacement:

3.10 L (3.28 US qt) (2.73 Imp.qt)

ECA11620

CAUTION:

●

●

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

“ENERGY CONSERVING II” or higher.

Make sure that no foreign material enters the crankcase.

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

NOTE:

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

ECA10400

CAUTION:

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

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

13. Install the cowling.

EAU20070

Coolant

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

EAU34010

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 an incorrect reading.

2. Check the coolant level in the coolant reservoir.

NOTE:

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

6-14

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Maximum level mark

2. Minimum level mark

3. If the coolant is at or below the minimum level mark, remove the brake fluid reservoir bracket screw, remove the coolant reservoir cap, and then add coolant to the maximum level mark.

1. Brake fluid reservoir bracket screw

1. Coolant reservoir cap

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

0.25 L (0.26 US qt) (0.22 Imp.qt)

ECA10470

CAUTION:

●

●

If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.

If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion.

6-15

●

If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.

EWA10380

WARNING

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

4. Install the coolant reservoir cap, and then install the brake fluid reservoir bracket screw.

NOTE:

●

The radiator fan is automatically switched on or off according to the coolant temperature in the radia-

● tor.

If the engine overheats, see page

6-44 for further instructions.

EAU33030

Changing the coolant

EWA10380

WARNING

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

6

U5VY10E0.book Page 16 Thursday, December 11, 2003 8:48 AM

6

PERIODIC MAINTENANCE AND MINOR REPAIR

The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a

Yamaha dealer change the coolant.

EAU34020

Replacing the air filter element

The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.

1. Remove the rider seat. (See page

3-15.)

2. Remove panels B and D. (See page 6-8.)

3. Remove the bolts.

●

●

EWA10410

WARNING

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.

5. Remove the rubber cap, and then remove the air filter case cover by removing the screws.

1. Bolt

4. Lift the front of the fuel tank, and then tilt it back and away from the air filter case. (Do not disconnect the fuel hoses!)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6. Remove the air filter element.

1. Rubber cap

1. Screw

2. Air filter case cover

ECA12880

CAUTION:

When removing the air filter case cover, be careful not to allow foreign objects to drop into the air intake manifold.

1. Air filter element

7. Install a new air filter element into the air filter case.

ECA10480

CAUTION:

●

●

Make sure that the air filter element is properly seated in the air filter case.

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

8. Install the air filter case cover by installing the screws, and then install the rubber cap.

6-17

9. Place the fuel tank in its original position, and then install the bolts.

EWA12380

WARNING

●

●

●

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

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

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

1. Fuel tank breather/overflow hose

6

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PERIODIC MAINTENANCE AND MINOR REPAIR

10. Install the panels.

11. Install the rider seat.

EAU21380

Adjusting the throttle cable free play

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.

1. Throttle cable free play

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

6-18

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PERIODIC MAINTENANCE AND MINOR REPAIR

Tires

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

EAU21750

Tire air pressure

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

EWA10500

WARNING

●

●

The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).

The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model.

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

90–201 kg (198–443 lb) (CAL)

90–202 kg (198–445 lb) (U49):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

Maximum load*:

201 kg (443 lb) (CAL)

202 kg (445 lb) (U49)

* Total weight of rider, passenger, cargo and accessories

EWA10510

WARNING

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

6-19

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

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

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

6

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

Tire inspection

●

●

EWA10580

WARNING

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

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

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

1. Tire sidewall

2. Tire wear indicator

3. Tire tread depth

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

Tire information

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

EWA10480

WARNING

●

●

●

●

The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed.

After extensive tests, only the tires listed below have been approved for this model by

Yamaha Motor Co., Ltd.

Always make sure that the valve caps are securely installed to prevent air pressure leakage.

Use only the tire valves and valve cores listed below to avoid tire deflation during a high-speed ride.

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)

1. Tire air valve

2. Tire air valve core

3. Tire air valve cap with seal

6-20

U5VY10E0.book Page 21 Thursday, December 11, 2003 8:48 AM

Front tire:

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

MICHELIN/Pilot POWER C

DUNLOP/D218FL

Rear tire:

Size:

190/50 ZR17M/C (73W)

Manufacturer/model:

MICHELIN/Pilot POWER G

DUNLOP/D218L

FRONT and REAR:

Tire air valve:

TR412

Valve core:

#9000A (original)

EWA10600

WARNING

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

●

Use only the specified replacement tires. Other tires may run

●

the danger of bursting at super high speeds.

Brand-new tires can have a relatively poor grip on certain road surfaces until they have been

PERIODIC MAINTENANCE AND MINOR REPAIR

●

●

“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 short-

● ened tire life.

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

6-21

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU33890

Adjusting the clutch lever free play

NOTE:

If the specified clutch lever free play cannot be obtained as described above, proceed as follows.

1. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable.

2. Loosen the locknut at the crankcase.

3. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b).

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

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

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

1. Locknut

2. Clutch lever free play adjusting nut

(crankcase)

4. Tighten the locknut.

6-22

EAU22270

Adjusting the rear brake light switch

1. Rear brake light switch

2. Rear brake light switch adjusting nut

The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.

Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).

U5VY10E0.book Page 23 Thursday, December 11, 2003 8:48 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22390

Checking the front and rear brake pads

The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

point that the wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set.

Rear brake pads

EAU22500

EAU22580

Checking the brake fluid level

Front brake

EAU22410

Front brake pads

1. Minimum level mark

Rear brake

1. Brake pad wear indicator

Each front 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

1. Lining thickness

Check each rear brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set.

1. Minimum level mark

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

6

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6

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.

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.

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.

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PERIODIC MAINTENANCE AND MINOR REPAIR

Drive chain slack

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

EAU22760

NOTE:

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

EAU22770

To check the drive chain slack

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

NOTE:

When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it.

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.

To adjust the drive chain slack

EAU34310

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

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

Drive chain slack:

20.0–25.0 mm (0.79–0.98 in)

1. Drive chain slack

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

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Alignment marks

ECA10570

CAUTION:

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

6-25

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Tighten the locknuts, then the axle nut to their specified torques.

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 12 ft·lbf)

Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lbf)

EAU23021

Lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

ECA10581

CAUTION:

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

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

ECA11120

CAUTION:

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

2. Wipe the drive chain dry.

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

ECA11110

CAUTION:

Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23090

Checking and lubricating the cables

The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a

Yamaha dealer check or replace it.

EAU23110

Checking and lubricating the throttle grip and cable

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

EAU23140

Checking and lubricating the brake and clutch levers

Brake lever

Recommended lubricant:

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

EWA10710

WARNING

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

Clutch lever

6

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

6-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

Recommended lubricant:

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

EAU23200

Checking and lubricating the sidestand

Lubricating the swingarm

EAUM1650

pivots

The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease

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.

EWA10730

WARNING

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)

6-28

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23271

Checking the front fork

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

To check the condition

WARNING

EWA10750

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

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

To check the operation

1. Place the vehicle on a level 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:

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

EAU23280

Checking the steering

Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

1. Place a stand under the engine to raise the front wheel off the ground.

EWA10750

WARNING

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

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

6

6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.

Battery

EAU23440

1. Negative battery terminal

2. Battery

3. Positive battery terminal

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

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.

6-30

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PERIODIC MAINTENANCE AND MINOR REPAIR

●

●

EWA10760

WARNING

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

• EXTERNAL: Flush with plenty of water.

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

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

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

●

KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

To store the battery

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

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

3. Fully charge the battery before installation.

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

ECA10630

CAUTION:

●

●

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

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

Using a conventional battery

6-31

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.

6

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34052

Replacing the fuses

The main fuse and the electronic fuel injection fuse are located under the rid-

er seat. (See page 3-15.)

6

1. Main fuse

2. Electronic fuel injection spare fuse

3. Electronic fuel injection fuse

The fuse box, which contains the fuses for the individual circuits, is located behind the cowling shown.

1. Cowling

If a fuse is blown, replace it as follows.

NOTE:

Include steps 2–4 and 8–9 only for the fuses in the fuse box.

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

2. Remove the quick fasteners by pushing the center in with a screwdriver, then pulling the fastener out.

1. Quick fastener

3. Loosen and remove the quick fastener screws, and then slide the areas of the cowling shown forward.

1. Quick fastener screw

2. Cowling

4. Pull the cowling away from the motorcycle as shown.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Fuse box

2. Cowling

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

1. Spare fuse

2. Left radiator fan fuse

3. Right radiator fan fuse

4. Backup fuse (for odometer and clock)

5. Signaling system fuse

6. Ignition fuse

7. Headlight fuse

Specified fuses:

Main fuse:

50.0 A

Backup fuse:

10.0 A

Ignition fuse:

15.0 A

Headlight fuse:

25.0 A

Signaling system fuse:

10.0 A

Radiator fan fuse:

15.0 Ax 2

Electronic fuel injection fuse:

15.0 A

ECA10640

CAUTION:

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

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

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

6

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PERIODIC MAINTENANCE AND MINOR REPAIR

8. Place the cowling in its original position, and then install and tighten the quick fastener screws.

EAU33900

Replacing a headlight bulb

6

1. Slot

2. Projection

1. High beam headlight bulb

2. Low beam headlight bulb

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

NOTE:

Make sure that the projections are inserted into the slots.

9. Install the quick fasteners.

NOTE:

To install a quick fastener, push its pin back so that it protrudes from the fastener head, then insert the fastener and push the protruding pin in until it is flush with the fastener head.

To replace a high beam headlight bulb

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

1. Headlight bulb cover

2. Headlight coupler

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

1. Headlight bulb holder

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PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10790

WARNING

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

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:

●

Headlight bulb

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

●

Headlight lens

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

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

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

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

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

To replace a low beam headlight bulb

1. Remove the headlight bulb cover by turning it counterclockwise.

1. Headlight bulb cover

2. Disconnect the headlight coupler.

1. Headlight coupler

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

6

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Headlight bulb holder

EWA10790

WARNING

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

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

ECA10650

CAUTION:

Take care not to damage the following parts:

●

●

Headlight bulb

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

Headlight lens

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

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

5. Connect the headlight coupler.

6. Install the headlight bulb cover by turning it clockwise.

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

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

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24180

Tail/brake light

This model is equipped with an LED type of tail/brake light.

If the tail/brake light does not come on, have a Yamaha dealer check it.

EAU24201

Replacing a turn signal light bulb

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

EAU24310

Replacing the license plate light bulb

1. Remove the license plate light unit by removing the screws.

1. Screw

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

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

4. Install the lens by installing the screw.

ECA11190

CAUTION:

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

1. Screw

2. License plate light unit

2. Remove the socket (together with the bulb) by pulling it out.

1. License plate light bulb

6-37

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Remove the defective bulb by pulling it out.

4. Insert a new bulb into the socket.

5. Install the socket (together with the bulb) by pushing it in.

6. Install the license plate light unit by installing the screws.

EAU33910

Replacing an auxiliary light bulb

This model is equipped with two auxiliary lights. If an auxiliary light bulb burns out, replace it as follows.

1. Remove panel A (if replacing the left auxiliary light bulb) or panel C

(if replacing the right auxiliary light

bulb). (See page 6-8.)

2. Remove the auxiliary light bulb cover by removing the quick fastener.

NOTE:

Remove the quick fastener by pushing the center pin in with a screwdriver, then pulling the fastener out.

3. Remove the socket (together with the bulb) by pulling it out.

1. Auxiliary light bulb socket

4. Remove the defective bulb by pulling it out.

1. Quick fastener

2. Auxiliary light bulb cover

6-38

1. Auxiliary light bulb

5. Insert a new bulb into the socket.

6. Install the socket (together with the bulb) by pushing it in.

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PERIODIC MAINTENANCE AND MINOR REPAIR

7. Install the auxiliary light bulb cover by installing the quick fastener.

NOTE:

To install the quick fastener, push the center pin out so that it will protrude from the fastener head, insert the fastener into the auxiliary light bulb cover, and then push the protruding pin in until it is flush with the fastener head.

8. Install the panel.

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.

a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.

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

6-39

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

Front wheel

EAU24360

EAU34590

To remove the front wheel

●

●

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

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

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

1. Front wheel axle pinch bolt

2. Lift the front wheel off the ground according to the procedure on

page 6-39.

3. Remove the brake hose holder and reflector on each side by removing the bolt and nut.

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

1. Brake hose holder

2. Bolt and nut

3. Bolt

4. Brake caliper

5. Axle bolt

6. Reflector

5. Remove the axle bolt, push the wheel axle out from the left side, and then remove the wheel.

1. Wheel axle

ECA11050

CAUTION:

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

EAU34530

To install the front wheel

1. Lift the wheel up between the fork legs.

2. Insert the wheel axle.

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

4. Install the brake calipers by installing the bolts, and then tightening them to the specified torque.

6-40

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PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

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

7. Tighten wheel axle pinch bolt B, and then tighten pinch bolt A to the specified torque.

8. Retighten pinch bolt B to the specified torque.

Tightening torque:

Brake caliper bolt:

35 Nm (3.5 m·kgf, 25 ft·lbf)

5. Install the brake hose holders and reflectors by installing the bolts and nuts.

6. Secure the wheel axle by installing the axle bolt, and then tightening the axle bolt to the specified torque.

NOTE:

While tightening the axle bolt, hold the wheel axle with a 19-mm hexagon wrench to keep it from turning.

Tightening torque:

Wheel axle pinch bolt:

21 Nm (2.1 m·kgf, 15 ft·lbf)

9. Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle.

10. Tighten wheel axle pinch bolt D, and then tighten pinch bolt C to the specified torque.

11. Retighten pinch bolt D to the specified torque.

Tightening torque:

Wheel axle pinch bolt:

21 Nm (2.1 m·kgf, 15 ft·lbf)

1. Front wheel axle pinch bolt A

2. Front wheel axle pinch bolt B

3. Front wheel axle pinch bolt C

4. Front wheel axle pinch bolt D

12. While applying the front brake, push down hard on the handlebar several times to check for proper fork operation.

6

Tightening torque:

Axle bolt:

91 Nm (9.1 m·kgf, 66 ft·lbf)

6-41

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6

PERIODIC MAINTENANCE AND MINOR REPAIR

Rear wheel

EAU25311

To remove the rear wheel

●

●

EWA10820

WARNING

It is advisable to have a Yamaha dealer service the wheel.

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

1. Loosen the axle nut.

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Brake caliper

5. Brake caliper bracket

EAU25080

2. Lift the rear wheel off the ground according to the procedure on

page 6-39.

3. Remove the axle nut.

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

5. Turn the drive chain slack adjusting bolts fully in direction (a) and push the wheel forward.

6. Remove the drive chain from the rear sprocket.

NOTE:

● If the drive chain is difficult to remove, remove the wheel axle first, and then lift the wheel upward enough to remove the drive chain

● from the rear sprocket.

The drive chain cannot be disassembled.

7. While supporting the brake caliper bracket, pull the wheel axle out, and then remove the wheel.

1. Wheel axle

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.

EAU25661

To install the rear wheel

1. Install the wheel and the brake caliper bracket by inserting the wheel axle from the left-hand side.

NOTE:

●

Be sure to insert the retainer on the brake caliper bracket into the slot in the swingarm.

6-42

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PERIODIC MAINTENANCE AND MINOR REPAIR

● Make sure that there is enough space between the brake pads before installing the wheel.

1. Retainer

2. Slot

2. Install the drive chain onto the rear sprocket.

3. Install the axle nut, and then lower the rear wheel so that it is on the ground.

4. Adjust the drive chain slack. (See page 6-25.)

5. Tighten the axle nut to the specified torque.

EAU25870

Troubleshooting

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

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

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

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

Tightening torque:

Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lbf)

6

6-43

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PERIODIC MAINTENANCE AND MINOR REPAIR

6

Troubleshooting charts

Starting problems or poor engine performance

WARNING

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

1. Fuel

Check the fuel level in the fuel tank.

There is enough fuel.

Check the compression.

There is no fuel.

Supply fuel.

The engine does not start.

Check the compression.

2. Compression

Operate the electric starter.

There is compression.

Check the ignition.

There is no compression.

Have a Yamaha dealer check the vehicle.

3. Ignition

Remove the spark plugs and check the electrodes.

Wet

Dry

Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Open the throttle halfway and operate the electric starter.

The engine does not start.

Check the battery.

4. Battery

Operate the electric starter.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

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

The engine does not start.

Have a Yamaha dealer check the vehicle.

6-44

EAU25911

EWA10840

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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.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is low.

Check the cooling system for leakage.

The coolant level is OK.

There is leakage.

Have a Yamaha dealer check and repair the cooling system.

There is no leakage.

Add coolant. (See NOTE.)

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

Yamaha dealer check and repair the cooling system.

6

NOTE:

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

6-45

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7

MOTORCYCLE CARE AND STORAGE

Care

EAU26020

While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.

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

Before cleaning

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

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

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

Cleaning

ECA11140

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, other plastic parts, and the muffler. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. However, if the muffler cannot be thoroughly cleaned with mild detergent, alkaline products and a soft brush may be used.

7-1

●

●

●

Do not use any harsh chemical products on plastic parts or the muffler. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.

Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), storage compartments, 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 hid-

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MOTORCYCLE CARE AND STORAGE den part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.

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.

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. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces (except the titanium muffler) to prevent corrosion.

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

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

Cleaning the titanium muffler

This model is equipped with a titanium muffler, which requires the following special care.

● Use only a soft, clean cloth or sponge with mild detergent and water to clean the titanium muffler.

However, if the muffler cannot be

●

●

● thoroughly cleaned with mild detergent, alkaline products and a soft brush may be used.

Never use compounds or other special treatments to clean the titanium muffler, as they will remove the finish on the outer surface of the muffler.

Even the smallest amounts of oil, such as from oily towels or fingerprints, will leave stains on the titanium muffler, which can be removed with a mild detergent.

Note that the thermally induced discoloring of the portion of the exhaust pipe leading into the titanium muffler is normal and cannot be removed.

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.

7

7-2

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7

MOTORCYCLE CARE AND STORAGE

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

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

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

7. Wax all painted surfaces.

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

EWA11130

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 riding at higher speeds, test the motorcycle’s braking performance and cornering behavior.

ECA10800

CAUTION:

●

●

●

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

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

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

NOTE:

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

Storage

EAU26201

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

7-3

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MOTORCYCLE CARE AND STORAGE

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

from corrosion.

a. Remove the spark plug caps and spark plugs.

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

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

EWA10950

WARNING

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

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

5. 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.

6. Cover the muffler outlets with plastic bags to prevent moisture from entering them.

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

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

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

6-30.

NOTE:

Make any necessary repairs before storing the motorcycle.

7

7-4

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8

SPECIFICATIONS

Dimensions:

Overall length:

2065 mm (81.3 in)

Overall width:

720 mm (28.3 in)

Overall height:

1105 mm (43.5 in)

Seat height:

835 mm (32.9 in)

Wheelbase:

1395 mm (54.9 in)

Ground clearance:

135 mm (5.31 in)

Minimum turning radius:

3400 mm (133.9 in)

Weight:

With oil and fuel:

193.0 kg (425 lb) (U49)

194.0 kg (428 lb) (CAL)

Engine:

Engine type:

Liquid cooled 4-stroke, DOHC

Cylinder arrangement:

Forward-inclined parallel 4-cylinder

Displacement:

998.0 cm³ (60.90 cu.in)

Bore

×

stroke:

77.0

×

53.6 mm (3.03

×

2.11 in)

Compression ratio:

12.40 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0

°

10

°

30

°

50

°

70

°

90

°

110

°

130

°

F

YAMALUBE 4 (10W30) or SAE 10W30

YAMALUBE 4 (20W40) or SAE 20W40

–20

°

–10

°

0

°

10

°

20

°

30

°

40

°

50

°

C

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter cartridge replacement:

2.90 L (3.07 US qt) (2.55 Imp.qt)

With oil filter cartridge replacement:

3.10 L (3.28 US qt) (2.73 Imp.qt)

Cooling system:

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

0.25 L (0.26 US qt) (0.22 Imp.qt)

Radiator capacity (including all routes):

2.76 L (2.92 US qt) (2.43 Imp.qt)

Air filter:

Air filter element:

Oil-coated paper element

Fuel:

Recommended fuel:

Premium unleaded gasoline only

8-1

Fuel tank capacity:

18.0 L (4.76 US gal) (3.96 Imp.gal)

Fuel reserve amount:

3.4 L (0.90 US gal) (0.75 Imp.gal)

Electronic fuel injection:

Manufacturer:

DENSO

Model:

297500-0300/4

Spark plug(s):

Manufacturer/model:

NGK/CR9EK

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

65/43 (1.512)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

45/17 (2.647)

Transmission type:

Constant mesh 6-speed

Operation:

Left foot operation

Gear ratio:

1st:

38/15 (2.533)

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

2nd:

33/16 (2.063)

3rd:

37/21 (1.762)

4th:

35/23 (1.522)

5th:

30/22 (1.364)

6th:

33/26 (1.269)

Chassis:

Frame type:

Diamond

Caster angle:

24.00 °

Trail:

97.0 mm (3.82 in)

Front tire:

Type:

Tubeless

Size:

120/70 ZR17M/C (58W)

Manufacturer/model:

MICHELIN/Pilot POWER C

Manufacturer/model:

DUNLOP/D218FL

Rear tire:

Type:

Tubeless

Size:

190/50 ZR17M/C (73W)

Manufacturer/model:

MICHELIN/Pilot POWER G

Manufacturer/model:

DUNLOP/D218L

Loading:

Maximum load:

201 kg (443 lb) (CAL)

202 kg (445 lb) (U49)

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

Tire air pressure (measured on cold tires):

Loading condition:

0–90 kg (0–198 lb)

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

Loading condition:

90–201 kg (198–443 lb) (CAL)

90–202 kg (198–445 lb) (U49)

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

Front wheel:

Wheel type:

Cast wheel

Rim size:

17M/C x MT3.50

SPECIFICATIONS

Rear wheel:

Wheel type:

Cast wheel

Rim size:

17M/C x MT6.00

Front brake:

Type:

Dual disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Single disc brake

Operation:

Right foot operation

Recommended fluid:

DOT 4

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

120.0 mm (4.72 in)

Rear suspension:

Type:

Swingarm (link suspension)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

130.0 mm (5.12 in)

8

8-2

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8

SPECIFICATIONS

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

A.C. magneto

Battery:

Model:

YTZ10S

Voltage, capacity:

12 V, 8.6 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 55.0 W

×

4

Tail/brake light:

LED

Front turn signal/position light:

12 V, 21 W/5.0 W

×

2

Rear turn signal light:

12 V, 21.0 W

×

2

Auxiliary light:

12 V, 5.0 W

×

2

Licence plate light:

12 V, 5.0 W

×

1

Meter lighting:

LED

Neutral indicator light:

LED

High beam indicator light:

LED

Oil level warning light:

LED

Turn signal indicator light:

LED

Fuel level warning light:

LED

Engine trouble warning light:

LED

Shift timing indicator light:

LED

Fuses:

Main fuse:

50.0 A

Headlight fuse:

25.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

15.0 A

Radiator fan fuse:

15.0 Ax 2

Electronic fuel injection fuse:

15.0 A

Backup fuse:

10.0 A

8-3

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EAU26351

Identification numbers

Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

KEY IDENTIFICATION NUMBER:

Key identification number

VEHICLE IDENTIFICATION

NUMBER:

MODEL LABEL INFORMATION:

CONSUMER INFORMATION

EAU26381

Vehicle identification number

EAU26400

1. Key identification number

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

1. Vehicle identification number

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

Record this number in the space provided.

NOTE:

The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area.

9

9-1

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CONSUMER INFORMATION

EAU33940

Model label

9

1. Model label

The model label is affixed to the frame

under the passenger seat. (See page

3-15.) Record the information on this la-

bel in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

EWA12370

WARNING

Do not touch the muffler bracket until the exhaust system has cooled.

1. Muffler bracket

9-2

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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

9

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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

9-4

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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.

Date of service

Mileage

Servicing dealer name and address

Remarks

Maintenance interval

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

24000 mi

(37000 km) or

36 months

28000 mi

(43000 km) or

42 months

32000 mi

(49000 km) or

48 months

9-5

9

9

U5VY10E0.book Page 6 Thursday, December 11, 2003 8:48 AM

CONSUMER INFORMATION

Maintenance interval

36000 mi

(55000 km) or

54 months

40000 mi

(61000 km) or

60 months

Date of service

Mileage

Servicing dealer name and address

Remarks

9-6

U5VY10E0.book Page 7 Thursday, December 11, 2003 8:48 AM

CONSUMER INFORMATION

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

EAU26661

WARRANTY

9

9-7

9

U5VY10E0.book Page 8 Thursday, December 11, 2003 8:48 AM

CONSUMER INFORMATION

9-8

U5VY10E0.book Page 9 Thursday, December 11, 2003 8:48 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.).

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

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

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

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

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

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

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

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

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

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

In addition, Travel and Recreation Interruption Protection

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

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

Y.E.S. plan period.

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

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

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

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

Extended Service.

9

9-9

9

U5VY10E0.book Page 10 Thursday, December 11, 2003 8:48 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)

9-10

U5VY10E0.book Page 1 Thursday, December 11, 2003 8:48 AM

A

B

Air filter element, replacing ………………. 6-16

Auxiliary light bulb, replacing ……………. 6-38

C

Battery ………………………………………….. 6-30

Brake and clutch levers, checking and lubricating ……………………………………. 6-27

Brake fluid, changing ………………………. 6-24

Brake fluid level, checking ……………….. 6-23

Brake lever ……………………………………. 3-12

Brake pedal …………………………………… 3-13

Cables, checking and lubricating ………. 6-27

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

Care ……………………………………………….. 7-1

Catalytic converter………………………….. 3-15

Clutch lever……………………………………. 3-11

Clutch lever free play, adjusting ……….. 6-22

Coolant …………………………………………. 6-14

Coolant temperature warning light………. 3-3

Cowling and panels, removing and installing ……………………………………….. 6-8

D

E

Dimmer switch ……………………………….. 3-11

Drive chain, lubricating ……………………. 6-26

Drive chain slack ……………………………. 6-25

Engine break-in ……………………………….. 5-3

Engine oil and oil filter cartridge ……….. 6-11

Engine stop switch………………………….. 3-11

Engine trouble warning light ………………. 3-5

EXUP system ………………………………… 3-21

F

Front and rear brake pads, checking …. 6-23

H

Front fork, adjusting …………………………3-17

Front fork, checking………………………….6-29

Fuel ……………………………………………….3-14

Fuel level warning light……………………….3-3

Fuel tank cap…………………………………..3-13

Fuses, replacing ………………………………6-32

Handlebar switches ………………………….3-10

Headlight bulb, replacing…………………..6-34

Helmet holders ………………………………..3-16

High beam indicator light…………………….3-2

Horn switch …………………………………….3-11

I

K

Identification numbers ………………………..9-1

Ignition circuit cut-off system ……………..3-22

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

Key identification number……………………9-1

L

M

Labels, location of ……………………………..1-5

License plate light bulb, replacing ………6-37

Luggage strap holders ……………………..3-21

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

Multi-function meter unit……………………..3-5

N

Neutral indicator light …………………………3-2

Noise regulation ………………………………..9-4

INDEX

O

P

Oil level warning light ………………………… 3-2

R

Parking……………………………………………. 5-4

Part locations …………………………………… 2-1

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

S

Rear brake light switch, adjusting ……… 6-22

T

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

Safety information …………………………….. 1-1

Seats…………………………………………….. 3-15

Shifting……………………………………………. 5-2

Shift pedal ……………………………………… 3-12

Shift timing indicator light …………………… 3-5

Shock absorber assembly, adjusting …. 3-18

Sidestand………………………………………. 3-21

Sidestand, checking and lubricating ….. 6-28

Spark plugs, checking……………………… 6-10

Specifications…………………………………… 8-1

Starting the engine……………………………. 5-1

Start switch ……………………………………. 3-11

Steering, checking ………………………….. 6-29

Storage …………………………………………… 7-3

Supporting the motorcycle ……………….. 6-39

Swingarm pivots, lubricating …………….. 6-28

Tail/brake light ……………………………….. 6-37

Throttle cable free play, adjusting ……… 6-18

Throttle grip and cable, checking and lubricating ……………………………………. 6-27

Tires……………………………………………… 6-19

Tool kit ……………………………………………. 6-1

Troubleshooting ……………………………… 6-43

U5VY10E0.book Page 2 Thursday, December 11, 2003 8:48 AM

INDEX

V

Troubleshooting charts ……………………. 6-44

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

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

Turn signal switch …………………………… 3-11

Valve clearance, adjusting ……………….. 6-18

Vehicle identification number ……………… 9-1

W

Warranty, extended…………………………… 9-9

Warranty, limited ………………………………. 9-7

Wheel bearings, checking………………… 6-30

Wheel (front) ………………………………….. 6-40

Wheel (rear) …………………………………… 6-42

Wheels ………………………………………….. 6-21

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN

2003.12-5.3

×

1 CR

(E)

LIT-11626-17-55

OWNER’S MANUAL

YZF-R1S(C)

5VY-28199-10