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Yamaha Motorcycle YZF-R1S User's Manual

1. 2 Compression There is compression t Check the ignition Operate the electric starter Have a Yamaha dealer check the vehicle There is no compression gt 3 Ignition Wet Pa Wipe off with a dry cloth and correct the Open the throttle halfway and operate spark plug gaps or replace the spark plugs the electric starter Remove the spark plugs i and check the electrodes The engine does not start gt Dry gt Have a Yamaha dealer check the vehicle Check the battery 4 Battery 7 The engine turns over The battery is good quickly The engine does not start Operate the electric starter gt Have a Yamaha dealer Pa The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 6 42 EAU25911 EWA10840 PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating e 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 e 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 soun
2. EAU12370 Pass switch PASS Press this switch to flash the head lights EAU12400 Dimmer switch 0 2z0 Set this switch to O for the high beam and to zo for the low beam EAU12460 Turn signal switch lt gt To signal a right hand turn push this switch to 2 To signal a left hand turn push this switch to lt When re leased the switch returns to the center 3 14 position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch gt Press this switch to sound the horn EAU12660 Engine stop switch ON Set this switch to CQ before starting the engine Set this switch to sy to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU12733 Hazard switch A With the key in the ON or p lt posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard ECA10061 CAUTION Do not use the hazard lights for an extended length of
3. 0 ccceeeeeeeeeeeseeeeeee Pre operation check list R Rear brake light switch adjusting 6 21 S Safety information eee eee 1 1 Seat height adjusting 3 26 SOAS sinnata 3 19 Shifting 5 2 Shift pedal 3 15 Shift timing indicator light 3 7 Shock absorber assembly adjusting 3 23 SideStand ccsceeseesseeeeseessseeseeeseeees 3 27 Sidestand checking and lubricating 6 26 Spark plugs checking 0 c eee 6 7 Specifications 8 4 Starting the engine 5 1 Start switch a an 3 14 Steering Checking c ces 6 28 Stora gE cect adv teosaadasters 7 3 Supporting the motorcycle 6 37 Swingarm pivots lubricating 6 27 T Tail brake light eee eeeeeeees 6 35 Throttle cable free play checking 6 16 Throttle grip and cable checking and lubricating 6 25 WN OS tent Sos casceh aenar aer e EE A 6 17 INDEX Toolkits dendaan diaa Troubleshooting Troubleshooting charts s Turn signal indicator lights Turn signal light bulb replacing Turn signal switch eee V Valve clearance sesesriseserreisinrens Vehicle identification number W Wheel bearings checking 0 6 28 Wheel front cece eee eeeeeneeeeaes 6 38 Wheel rear eeceseesseeeseeesseesseeeesees 6 40 YAMAHA YAMAHA MOTOR CO LTD PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005 10 0
4. DECLARATION of CONFORMITY We Company MORIC CO LTD Address 1450 6 Mori Mori Machi Shuchi gun Shizuoka 437 0292 Japan Hereby declare that the product Kind of equipment IMMOBILIZER Type designation 5SL 00 is in compliance with following norm s or documents R amp TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue 1 Aug 2002 Revolution record No Contents Date 1 To change contact person and integrate type designation 9 Jun 2005 a General manager of quality assurance div 7 a representative name and signature MORIC CO LTD 1450 6 Mori machi Shuchi gun Shizuoka 437 0292 JAPAN Telephone 81 538 85 0757 Facsimile 81 538 85 0456 URL http www morie jp com EAU26942 INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling As the owner of the YZF R1S you are benefiting from Yamaha s vast experience and newest technology regarding the de sign and manufacture of high quality products which have earned Yamaha a reputation for dependability Please take the time to read this manual thoroughly so as to enjoy all advantages of your YZF R1S The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard
5. 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 bolt remove the coolant reservoir cap and then add coolant to the maxi mum level mark 1 Brake fluid reservoir bracket bolt 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 e If water has been used instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion e 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 Never attempt to remove the radiator cap when the engine is hot EWA10380 4 Install the coolant reservoir cap and then install the brake fluid res ervoir bracket bolt NOTE e The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor f the engine overheats see page 6 42 for further instructions EAU33030 Changing the coolant Never attempt to remove the radiator cap wh
6. If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EWA10730 Recommended lubricant The operation of the brake and clutch Fipiani soap babed crease ipur levers should be checked before each ride and the lever pivots should be lu bricated if necessary pose grease 6 26 EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 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 main tenance and lubrication chart To check the condition Securely support the vehicle so that there is no danger of it falling over EWA10750 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 6 27 ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering Worn or lo
7. BLE e Always turn the engine off when refueling e Take care not to spill any gaso line on the engine or exhaust system when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has ad equate ventilation A SAFETY INFORMATION e Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright If the motorcycle should lean over gasoline may leak out of the fuel tank If you should swallow any gaso line inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin 1 4 or clothing immediately wash the affected area with soap and water and ch
8. whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU33890 Adjusting the clutch lever free play 1 Clutch lever free play adjusting bolt 2 Clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free play turn the adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 6 20 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 loos en the clutch cable 2 Loosen the locknut at the crank case 3 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn the adjusting nut in direction b 1 Locknut 2 Clutch lever free play adjusting nut crank case 4 Tighten the locknut EAU22270 Adjusting the rear brake light switch 1 Rear brake light switch 2 R
9. 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SE LECT button The stopwatch digits will start flashing Release the SE LECT button and then push it again for a few seconds until the stopwatch digits stop flashing INSTRUMENT AND CONTROL FUNCTIONS Standard measurement 1 Push the RESET button to start the stopwatch 2 Push the SELECT button to stop the stopwatch 3 Push the SELECT button again to reset the stopwatch 3 Split time measurement 1 Push the RESET button to start the stopwatch 2 Push the RESET button or start switch to measure split times The colon will start flashing 3 Push the RESET button or start switch 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 NOTE To change the display back to the prior mode push the SELECT button for a few seconds Coolant temperature display Air intake temperature display 1 Coolant temperature display The coolant temperature display indi cates the temperature of the coolant Push the RESET button to switch the coolant temperature display to the air intake temperature display NOTE When the coolant temperature display is selected C is displayed for one second and then the
10. A mark on the brake lever 3 16 EAU12941 Brake pedal 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 EAU13070 Fuel tank cap vf 1 Fuel tank cap lock cover 2 Unlock To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover INSTRUMENT AND CONTROL FUNCTIONS NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked Make sure that the fuel tank cap is properly closed before riding EWA11090 3 17 EAU13220 Fuel 2 1 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler tube as shown e Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands e Avoid spilling fuel on the hot en gine EWA10880 INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION Im
11. BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice EWA10030 IMPORTANT MANUAL INFORMATION EAU10200 YZF R1S OWNER S MANUAL 2005 by Yamaha Motor Co Lid 1st edition September 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan TABLE OF CONTENTS SAFETY INFORMATION 1 1 DESCRIPTION o 2 1 Left VEW anttia a 2 1 Right ViOW esere 2 2 Controls and instruments 2 3 INSTRUMENT AND CONTROL FUNCTIONS aaee 3 1 Immobilizer system s 3 1 Main switch steering lock 3 2 Indicator and warning lights 3 3 Multi function meter unit 3 8 Anti theft alarm optional 3 13 Handlebar switches seee 3 14 Clutch lever oo eeeeeeeeeeseeeeeeeeeeeee 3 15 Shift pedal 0 0 eeeeeeeeeeeeseeeeeeees 3 15 Brake lever ceceeeseeeeeeseeeeeeeeees 3 16 Brake pedal eeeeseeeeseeeeeneeeees 3 16 Fuel tank Cap ceecee 3 17 Fuel set itse a e a sisters 3 17 Fuel tank breather overflow NOSE EE EE TT 3 18 Catalytic converter s 3 19 SOAS aa aa r aias 3 19 Helmet holders 0 0 eeeeeeeeeeeeeeees 3 20 Adjusting the front fork n se 3 21 Adjusting the shock absorber assembly ineeie 3 23 Adjusting the seat height 3 26 Luggage strap holders 3
12. Backup fuse 10 0A Ignition fuse 15 0A Headlight fuse 25 0A Signaling system fuse 10 0A Turn signal light fuse Radiator fan fuse 150Ax2 Fuel injection system fuse 15 0A ECA10640 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 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 8 Place the cowling in its original po sition and then install and tighten the quick fastener screws 1 Slot 2 Projection NOTE Make sure that the projections are in serted into the slots 9 Install the quick fasteners NOTE To install a quick fastener push its pin back so that it protrudes from the fas tener head then insert the fastener and push the protruding pin in until it is flush with the fastener head 6 32 33900 Replacing a headlight bulb 2 1 IL 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 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
13. Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 200 kg 198 441 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 86 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Forged wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Forged wheel Rim size 17M C x MT6 00 8 2 SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 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 Electrical system Ignition system Transistorized coil ignition digital Charging system AC magneto SPECIFICATIONS Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12V 550Wx4 Tail brake light LED Front turn signal light 12V 10 0Wx2 Rear turn signal light 12V 10 0Wx2 Auxiliary light 12V 50Wx2 License plate light 12V 50Wx1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil
14. Minimum soft 42 click s in direction b Standard 30 click s in direction b Maximum hard 1 click s in direction b With the adjusting bolt fully turned in direction a Compression damping force for slow compression damping To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw in direction a To decrease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b Compression damping setting for slow compression damping Minimum soft 17 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 NOTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the specifica tions listed due to small differences in production the actual number of clicks always represents the entire adjust ment range To obtain a precise adjust ment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to mod ify the specifications as necessary This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury th
15. Rapiacinathe EAU34053 If you do not have access toa Placing the tuses sealed type MF battery charg The main fuse and the fuel injection er have a Yamaha dealer SYStem fuse are located under the rider charge your battery seat See page 3 19 1 Cowling If a fuse is blown replace it as follows NOTE Include steps 2 4 and 8 9 only for the e Mainituse fuses in the fuse box 2 Fuel injection system fuse 3 Fuel injection system spare fuse 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 screw driver then pulling the fastener out The fuse box which contains the fuses for the individual circuits is located be hind the cowling shown 6 30 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Quick fastener 1 Fuse box 1 Headlight fuse p 2 Cowling 2 Spare fuse 3 Loosen and remove the quick fas 3 Left radiator fan fuse tener screws and then slide the 5 Remove the blown fuse and then 4 Right radiator fan fuse areas of the cowling shown for install a new fuse of the specified 5 Backup fuse for odometer clock and immo ward amperage bilizer system 6 Turn signal light fuse e 7 Signaling system fuse Woe 1 7 8 Ignition fuse 1 Quick fastener screw 2 Cowling 4 Pull the cowling away from the motorcycle as shown PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses Main fuse 50 0A
16. ar eas seals of wheel and swing arm bearings fork and brakes storage compartments electric components couplers connec tors instruments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound _ after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads MOTORCYCLE CARE AND STORAGE NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down ECA10790 CAUTION Do not use warm wat
17. check the system be fore riding EWA10250 3 28 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off NOTE eee This check is most reliable if performed with 2 Make sure that the engine stop switch is turned on p 3 Turn the key on a warmed up engine 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The system is OK The motorcycle can be ridden 3 29 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 i
18. coolant tempera ture is displayed ECA10020 CAUTION Do not operate the engine if it is overheated 3 10 1 Air intake temperature display The air intake temperature display indi cates the temperature of the air drawn into the air filter case Push the RE SET button to switch the coolant tem perature display to the air intake temperature display NOTE e 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 auto matically 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 diag nosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on and then the right display will indi cate a two digit error code e g 11 12 13 This model is also equipped with a self diagnosis device for the immobilizer system If any of the immobilizer system circuits are defective the immobilizer system indicator light will flash and then the right display will indicate a two digit er ror code e g 51 52 53 NOTE If the right display indicates error code 52 this could be cau
19. helmet is the single most critical factor in the pre vention or reduction of head injuries Always wear an approved helmet e 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 e Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to f
20. level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0Ax2 Turn signal light fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 10 0 A 8 3 EAU26351 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen KEY IDENTIFICATION NUMBER Ee VEHICLE IDENTIFICATION NUMBER oo MODEL LABEL INFORMATION CONSUMER INFORMATION EAU26381 Key identification number S gt 2 1 Key identification number 2 Code re registering key red bow 3 Standard keys black bow 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 Vv 1 3 N EAU26400 Vehicle identification number 1 J 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification nu
21. lubrication are explained on the following pages The intervals given in the periodic maintenance and lubrication chart should be simply considered as a gen eral guide under normal riding condi tions However DEPENDING ON THE WEATHER TERRAIN GEOGRAPHI CAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORT ENED If you are not familiar with mainte nance work have a Yamaha dealer do it for you EWA10320 PERIODIC MAINTENANCE AND MINOR REPAIR EAU33881 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 19 The service information included in this manual and the tools provided in the owners tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 6 1 EWA10350 Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempting any chang es Do not touch either muffler bracket located under the muffler bracket covers until the exhaust system has cooled EWA12371 1 Muffler bracket cover 2 Muffler bracket PERIODIC MAINTENANCE AN
22. on 1 Projection 2 Seat holder 2 Remove the key NOTE Make sure that the seats are properly secured before riding EAU33870 Helmet holders 1 Helmet holder The helmet holders are located on the bottom of the passenger seat To secure a helmet to a helmet hold er 1 Remove the passenger seat See page 3 19 2 Attach the helmet to a helmet hold er and then securely install the passenger seat Never ride with a helmet attached to a helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EWA11040 3 20 To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat INSTRUMENT AND CONTROL FUNCTIONS EAU39282 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting bolts and compres sion damping force adjusting bolts EWA10180 A WARNING Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload To make any adjustment of the spring preload the adjuster has to be set to the standard position first To find the standard position start by turning the adjusting bolt on each fork leg in direction a until it stops then check the alignment mark position a If the alignment mark on the ad justing bolt is positioned past the alignment mar
23. raise it 5 2 ECA10260 CAUTION e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission e Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16810 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption e Shift up swiftly and avoid high en gine speeds during acceleration Donotrev the engine while shifting down and avoid high engine speeds with no load on the engine e Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings OPERATION AND IMPORTANT RIDING POINTS EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During t
24. the brake fluid e Replace the brake hoses every four years and if cracked or damaged 6 5 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 1 Panel C 2 Panel D EAU36630 Panels A and C To remove one of the panels Remove the screw and the quick fas tener and then pull the panel off as shown 1 Screw 2 Panel A 3 Quick fastener To install the panel Place the panel in the original position and then install the screw and the quick fastener PERIODIC MAINTENANCE AND MINOR REPAIR EAU33990 Panels B and D To remove one of the panels 1 Remove the rider seat See page 3 19 2 Remove the screw and then re move the panel as shown 1 Screw 2 Panel B To install the panel 1 Place the panel in its original posi tion and then install the screw 6 7 EAU19651 Checking the spark plugs 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 mainte nance and lubrication chart In addition the condition of the spark plugs can re
25. the defective bulb 1 Headlight bulb holder EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 3 Place anew headlight bulb into po sition and then secure it with the bulb holder ECA10650 CAUTION Take care not to damage the follow ing parts e Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner 6 33 PERIODIC MAINTENANCE AND MINOR REPAIR e 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 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Headlight bulb cover 2 Disconnect the headlight coupler 1 Headlight coupler 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight bulb holder Headli
26. then install the bolts 11 Install the rider seat EWA12380 A WARNING e 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 other wise fuel may leak e Make sure that the fuel hoses 1 Air filter element 7 Install a new air filter element into are properly connected and the air filter case routed and are not pinched ECA10480 e Be sure to place the fuel tank CAUTION p ee breather overflow hose in its Make sure that the air filter ele original position ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by in stalling the screws and then install the rubber cap 1 Fuel tank breather overflow hose 6 15 PERIODIC MAINTENANCE AND MINOR REPAIR EAU34300 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly re sponds to the throttle Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw
27. to the operating characteristics of the motor Manufacturer model conditions cycle cannot be guaranteed PIRELLI DIABLO CORSA e After extensive tests only the FRONT and REAR A Tire air valve tires listed below have been ap TR412 proved for this model by Valve core Yamaha Motor Co Lid 9100 original Always make sure that the valve caps are securely installed to prevent air pressure leakage e Use only the tire valves and This motorcycle is fitted with super valve cores listed below to high speed tires Note the following avoid tire deflation during a Points in order to make the most ef high speed ride ficient use of these tires e Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds e Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high EWA10600 6 19 PERIODIC MAINTENANCE AND MINOR REPAIR EAU39230 Forged wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced
28. tor are included in the owner s tool kit b Remove the engine oil filler cap with the special wrench as shown 1 Engine oil filler cap 2 Special wrench 3 Rubber protector c Add sufficient oil of the recom mended 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 replace ment 1 Unfasten the cowling by removing the bolt and by loosening and re moving the quick fastener screws 6 9 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Quick fastener screw 2 Bolt 3 Cowling 2 Slide the projection toward the rear of the vehicle to unhook the cowl ing then set the left side of the cowling down on the ground PERIODIC MAINTENANCE AND MINOR REPAIR NOTE An oil filter wrench is available at a Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1 Cowling 1 Engine oil drain bolt 2 Projection NOTE Skip steps 7 9 if the oil filter cartridge is 3 Start the engine warm it up for several minutes and then turn it off not being replaced 6 4 Place an oil pan under the engine 7 Remove the oil filter cartridge with to collect the used oil an oil filter wrench 4 O24 5 Remove the engine oil filler cap ies with the special wrench l NOTE 6 Remove the engine oil drain bolt to a drain the oil from the cran
29. vehicle 4 3 EAU15950 EWA10270 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion e Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control OPERATION AND IMPORTANT RIDING POINTS EAU33010 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sid estand up e Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 28 e Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to O EWA10290 ECA11730 CAUTION The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light F
30. 0 8 m kgf 5 8 ft Ibf 5 Place the cowling in its original po sition install and tighten the quick fastener screw and then install the bolt 6 Adjust the drive chain slack See page 6 23 INSTRUMENT AND CONTROL FUNCTIONS EAU15181 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 pas senger 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 19 EAU15281 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor ECA10191 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 dam age to the engine e If the EXUP system cannot be heard when the main switch is turned on have a Yamaha deal er check it 3 27 EAU15301 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 o
31. 27 EXUP system sses 3 27 Sidestand cceeceeeeeseeeeeeeeeeeteaes 3 27 Ignition circuit cut off system 3 28 PRE OPERATION CHECKS 4 1 Pre operation check list 4 2 OPERATION AND IMPORTANT RIDING POINTS ceeeeeeteeeeee 5 1 Starting the engine eee 5 1 Shifting wis aee eea 5 2 Tips for reducing fuel CONSUMPTION iseic 5 3 Engine break in ecce 5 3 Parkin enninu ttt hdd 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 00 00 eeeeeeeeeeeeeeees 6 1 Periodic maintenance and lubrication Chart eseese 6 2 Removing and installing panels 6 6 Checking the spark plugs 6 7 Engine oil and oil filter cartridge 6 8 COOMA ss 55 0032 tes5 n aiaa 6 12 Replacing the air filter element 6 14 Adjusting the engine idling Speed sneonen eni 6 16 Checking the throttle cable free play eeeceeeeeeceesereeeeseees 6 16 Valve clearance scce 6 17 Tires iinan an enai 6 17 Forged wheels necces 6 20 Adjusting the clutch lever free play 2 eeseeeeeseceeeeeeeeeserees 6 20 Adjusting the rear brake light SWICH sineta 6 21 Checking the front and rear brake pads seee 6 21 Checking the brake fluid level 6 22 Changing the brake fluid 6 23 Drive chain slack nee 6 23 Cleaning and lubricating the drive chain seene 6 24 Checking and lubricating the Cable nenen ayan 6 25 Checking and lubricating the t
32. 3x1 CR E
33. CE AND MINOR REPAIR Checking the brake fluid level Front brake 1 Minimum level mark Rear brake 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance 6 22 Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the caus
34. D MINOR REPAIR EAU17705 Periodic maintenance and lubrication chart NOTE The annual checks must be performed every year except if a kilometer based maintenance is performed in stead e From 50000 km repeat the maintenance intervals starting from 10000 km Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills CHECK OR MAINTENANCE JOB ODOMETER READING x 1000 km ANNUAL 1 10 20 30 40 CHECK Fuel line e Check fuel hoses for cracks or damage Ni v 4 y v Spark plugs e Check condition e Clean and regap NI e Replace Valves e Check valve clearance e Adjust Air filter element e Replace Clutch e Check operation e Adjust Front brake e Check operation fluid level and vehicle for fluid leakage v x Ni e Replace brake pads enever worn to the limit Rear brake e Check operation fluid level and vehicle for fluid leakage v 4 Ni e Replace brake pads enever worn to th e limit Brake hoses e Check for cracks or damage TE Ni e Replace Every 4 years Wheels e Check runout and for damage Vv 4 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING x 1000 km ANNUAL NO ITEM CHECK O
35. HECK gt e Change Engine oil e Check oil level and vehicle for oil leakage y V y y X Engine oil filter car tridge Replace V e Check coolant level and vehicle for coolant leakage V V Cooling system e Change Every 3 years Front and rear brake witches e Check operation V V Moving parts and ca bles e Lubricate Vy e Check operation and free play e Adjust the throttle cable free play if necessary e Lubricate the throttle grip housing and cable Throttle grip housing and cable e Check the air cut off valve reed valve and hose for dam Air induction system age e Replace any damaged parts if necessary Muffler and exhaust pipe EXUP system e Check operation cable free play and pulley position e Check the screw clamp for looseness Lights signals and e Check operation switches e Adjust headlight beam 6 4 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18680 NOTE e Air filter e This model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with com pressed air to avoid damaging it e The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service e Regularly check and if necessary correct the brake fluid level e Every two years replace the internal components of the brake master cylinders and calipers and change
36. LL ASPECTS OF MOTORCYCLE OPERATION e 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 e Always make __ pre operation checks Careful checks may help prevent an accident This motorcycle is designed to car ry the operator and a passenger e The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore e Wear a brightly colored jacket e Use extra caution when you are approaching and _ passing through intersections since in tersections are the most likely places for motorcycle accidents to occur 1 1 e Ride where other motorists can see you Avoid riding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many op erators who have been involved in accidents do not even have a cur rent motorcycle license Make sure that you are qualified and that you only lend your motorcycle to other qualified op erators Know your skills and limits Sta
37. R MAINTENANCE JOB 1 10 20 30 40 CHECK e Check tread depth and for damage 10 Tires Replace if necessary J J J N N e Check air pressure e Correct if necessary 11 Wheel bearings Check bearing for looseness or damage V V V V Check operation and for excessive play V V V V 12 Swingarm e Lubricate with lithium soap based grease Every 50000 km e Check chain slack alignment and condition 13 Drive chain e Adjust and lubricate chain with a special O ring chain lu Every coo km ee eee motoreygleior bricant thoroughly 9 Check bearing play and steering for roughness V V V V V 14 Steering bearings e Lubricate with lithium soap based grease Every 20000 km 15 Steering damper Check operation and for oil leakage V V V V 16 Chassis fasteners Make sure that all nuts bolts and screws are properly J N N J J tightened g e Check operation 17 Sidestand L bricate V V V V V 18 Sidestand switch Check operation V V V V V V 19 Front fork Check operation and for oil leakage V V V V 20 e absorber assem Check operation and shock absorber for oil leakage V V V V Rear suspension relay 21 arm and connecting Check operation V V V V arm pivoting points 22 Fuel injection Adjust engine idling speed and synchronization V V V V V V 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING x 1000 km ANNUAL ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40 C
38. The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately Minimum tire tread depth front and rear 1 6 mm 0 06 in NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations 6 18 EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control e The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information g 1 T H 1 Tire air valve 2 Tire air valve core 3 Tire air valve cap with seal PERIODIC MAINTENANCE AND MINOR REPAIR This motorcycle is equipped with forged speed riding to ride conserva wheels and tubeless tires with valves S tively for approximately 100 km Ease 120 70 ZR17M C 58W 60 mi after installing a new tire A WARNING Manufacturer model The tires must be warmed up The front and rear tires should a DIABLO CORSA H before a high speed run be of the same make and de Size e Always adjust the tire air pres sign otherwise the handling 190 50 ZR17M C 73W sure according
39. To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b 1 Idle adjusting screw EAU21381 Checking the throttle cable free play SES Engine idling speed 1150 1250 r min 1 Throttle cable free play NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment 6 16 The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU39210 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be ad justed in accordance with the riding speed a
40. all 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 23 5 Tighten the axle nut to the speci fied torque Tightening torque Axle nut 150 Nm 15 0 m kgf 110 ft Ibf 6 41 EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills PERIODIC MAINTENANCE AND MINOR REPAIR Troubleshooting charts Starting problems or poor engine performance Keep away open flames and do not smoke while checking or working on the fuel system 1 Fuel There is enough fuel gt Check the compression Check the fuel level in the fuel tank Th ined Ten e engine does not start Th fuel m ASIS ee Supply fuel Check the compression
41. and auxiliary lights come on and the engine can be start ed The key cannot be removed 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 EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved 3 2 To lock the steering 1 Push 2 Turn 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering 1 Push 2 Turn Push the key in and then turn it to OFF while still pushing it Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EWA10060 INSTRUMENT AND CONTROL FUNCTIONS EAU10941 p lt Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to p lt ECA11020 CAUTION Do no
42. ange your clothes DESCRIPTION Left view 1 Fuse box page 6 30 2 Front fork rebound damping force adjusting bolt page 3 21 3 Front fork spring preload adjusting bolt page 3 21 4 Front brake fluid reservoir page 6 22 5 Idle adjusting screw page 6 16 6 Shock absorber assembly spring preload adjusting knob page 3 23 7 Shock absorber assembly compression damping force adjusting bolt for fast compression damping page 3 23 EAU10410 8 Shock absorber assembly compression damping force adjusting screw for slow compression damping page 3 23 9 Battery page 6 29 10 Fuel injection system fuse page 6 30 11 Main fuse page 6 30 12 Owner s tool kit page 6 1 13 Engine oil drain bolt page 6 8 14 Engine oil filter cartridge page 6 8 Right view ANOaRWD 11109 Luggage strap holder page 3 27 Helmet holder page 3 20 Passenger seat lock page 3 19 Rear brake fluid reservoir page 6 22 Engine oil filler cap page 6 8 Air filter element page 6 14 Front fork compression damping force adjusting bolt page 3 21 Engine oil level check window page 6 8 DESCRIPTION EAU10420 9 Seat height adjusting bolt page 3 26 10 Shock absorber assembly rebound damping force adjusting screw page 3 23 11 Coolant reservoir page 6 12 DESCRIPTION EAU10430 Controls and instruments Clutch lever page 3 15 Left ha
43. at may result from improper handling e Do not tamper with or attempt to open the gas cylinder EWA10220 3 25 e Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure e Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance e Always have a Yamaha dealer service the shock absorber INSTRUMENT AND CONTROL FUNCTIONS EAU39261 Adjusting the seat height This model is equipped with a seat height adjusting bolt Adjust the seat height as follows 1 Remove the bolt loosen and re move the quick fastener screw and then pull the cowling away from the motorcycle 1 Quick fastener screw 2 Bolt 3 Cowling 2 Loosen the relay arm connecting rod bolts 1 Relay arm connecting rod 2 Relay arm connecting rod bolt 3 Seat height adjusting bolt 4 Distance A 3 To increase the seat height turn the adjusting bolt in direction a To decrease the seat height turn the adjusting bolt in direction b NOTE The longer distance A is the lower the seat height The shorter dis tance A is the higher the seat height e The minimum seat height is the standard setting adjusting bolt ful ly turned in direction b 4 Tighten the relay arm connecting rod bolts to their specified torque 3 26 Tightening torque Relay arm connecting rod bolt 8 0 Nm
44. cid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID e EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician e EYES Flush with water for 15 minutes and seek prompt medical attention e Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space 6 29 e 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 Ifthe battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals ECA10630 CAUTION e Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery PERIODIC MAINTENANCE AND MINOR REPAIR charger will damage the battery
45. cified level e Check hydraulic system for leakage 6 21 6 22 Clutch e Check operation e Lubricate cable if necessary e Check lever free play e Adjust if necessary 4 2 PRE OPERATION CHECKS CHECKS Throttle grip e Make sure that operation is smooth e Check cable free play e If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing Control cables e Make sure that operation is smooth e Lubricate if necessary Drive chain e Check chain slack e Adjust if necessary e Check chain condition e Lubricate if necessary Wheels and tires e Check for damage e Check tire condition and tread depth e Check air pressure e Correct if necessary Shift pedal e Make sure that operation is smooth e Correct if necessary Brake pedal e Make sure that operation is smooth e Correct if necessary Brake and clutch levers e Make sure that operation is smooth e Lubricate lever pivoting points if necessary Sidestand e Make sure that operation is smooth e Lubricate pivot if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened e Tighten if necessary Instruments lights signals and switches e Check operation e Correct if necessary Sidestand switch e Check operation of ignition circuit cut off system e If system is defective have Yamaha dealer check
46. d has stopped press down on the cap while turning it counterclockwise and then remove the cap EWA10400 There is Have a Yamaha dealer check The coolant level is low leakage and repair the cooling system m Check the cooling system for leakage There is Wait until the Check the coolant level in the ed no leakage Add coolant See NOTE engine has cooled reservoir and radiator j The coolant level Start the engine If the engine overheats again have a is OK Yamaha dealer check and repair the cooling system NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible 6 43 MOTORCYCLE CARE AND STORAGE EAU26020 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all el
47. digit code when the key is turned to ON When this occurs have a Yamaha 3 7 dealer check the self diagnosis system However if the indicator light slowly flashes five times and then quickly flashes two times repeatedly error code 52 will be displayed This error could be caused by signal interference If this occurs try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered INSTRUMENT AND CONTROL FUNCTIONS EAU33965 Multi function meter unit Clock Speedometer SELECT button RESET button Tachometer Coolant temperature display air intake tem perature display 7 Odometer tripmeters fuel reserve tripme ter stopwatch 8 Shift timing indicator light Be sure to stop the vehicle before making any setting changes to the multi function meter unit DDYN EWA12421 The multi function meter unit is equipped with the follow
48. dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA11110 CAUTION Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings PERIODIC MAINTENANCE AND MINOR REPAIR EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Engine oil EWA10720 A WARNING Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 EAU23200 Checking and lubricating the eset ate eer earl eal T gests Checking and lubricating the brake and clutch levers Se P sidestand Brake lever 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
49. e EAU22730 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22771 To check the drive chain slack 1 Place the motorcycle on the side stand NOTE When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown Drive chain slack 20 0 25 0 mm 0 79 0 98 in 6 23 1 Drive chain slack 4 If the drive chain slack is incorrect adjust it as follows EAU34311 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the sw
50. e the bolt loosen and re move the quick fastener screw and then pull the cowling away from the motorcycle 1 Quick fastener screw 2 Bolt 3 Cowling 2 To increase the rebound damping force and thereby harden the re bound damping turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damp ing turn the adjusting screw in di rection b r op 20 x L ON 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 18 click s in direction b Standard 14 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 po sition install and tighten the quick fastener screw and then install the bolt 3 24 Compression damping force 1 Compression damping force adjusting bolt for fast compression damping 2 Compression damping force adjusting screw for slow compression damping Compression damping force for fast compression damping To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt in direction a To decrease the compres sion damping force and thereby soften the compression damping turn the ad justing bolt in direction b INSTRUMENT AND CONTROL FUNCTIONS Compression damping setting for fast compression damping
51. ear brake light switch adjusting nut The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU36890 Front brake pads 1 Brake pad wear indicator Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to 6 21 PERIODIC MAINTENANCE AND MINOR REPAIR the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads 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 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set PERIODIC MAINTENAN
52. ectrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning ECA11140 CAUTION e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels other plastic parts and the muf fler Use only a soft clean cloth or sponge with mild detergent and water to clean plastic How ever if the muffler cannot be thoroughly cleaned with mild detergent alkaline products and a soft brush may be used 7 1 e 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 sol vent or thinner fuel gasoline rust removers or inhibitors brake fluid antifreeze or electro lyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following
53. electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit INSTRUMENT AND CONTROL FUNCTIONS CAUTION _ Do not operate the engine if it is overheated INSTRUMENT AND CONTROL FUNCTIONS Coolant temperature Display Conditions What to do Under 39 C Under 103 F Message LO is displayed OK Go ahead with riding 40 116 C 104 242 F ae rey Lit Temperature is displayed OK Go ahead with riding 117 139 C 243 283 F DN Of as N TRIPA_ IIN 73 1k au ci ae war J 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 42 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 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 8 for an explanation of the self diagnosis de vice The electrical circuit of the warning light can be checked by turning the key to ON I
54. en the engine is hot EWA10380 6 13 PERIODIC MAINTENANCE AND MINOR REPAIR The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant PERIODIC MAINTENANCE AND MINOR REPAIR EAU34020 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 3 19 2 Remove panels B and D See EWATOATO page 6 6 3 Remove the bolts e Make sure that the fuel tank is well supported e 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 6 14 Y Vy Cyt 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 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Remove the air filter element 9 Place the fuel tank in its original 10 Install the panels position and
55. er outlets with plas tic bags to prevent moisture from entering them Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see page 6 29 NOTE Make any necessary repairs before storing the motorcycle the engine over 7 4 SPECIFICATIONS Dimensions Overall length 2085 mm 82 1 in Overall width 720 mm 28 3 in Overall height 1105 mm 43 5 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3400 mm 133 9 in Weight With oil and fuel 195 0 kg 430 Ib Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined parallel 4 cylinder Displacement 998 0 cm 60 90 cu in Bore x stroke 77 0 x 53 6 mm 3 03 x 2 11 in Compression ratio 12 40 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 a0 ay 9 19 2D 90 40 50 C SAE 20W 50 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 C
56. er since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces except the tita nium muffler to prevent corrosion Cleaning the titanium muffler This model is equipped with a titanium muffler which requires the following special care e Use only a soft clean cloth or sponge with mild detergent and water to clean the titanium muffler However if the muffler cannot be 7 2 thoroughly cleaned with mild de tergent alkaline products and a soft brush may be used Never use compounds or other special treatments to clean the tita nium 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 finger prints will leave stains on the tita nium muffler which can be removed with a mild detergent Note that the thermally induced discoloring of the portion of the ex haust pipe leading into the titanium muffler is normal and cannot be re moved After cleaning 1 2 Dry the motorcycle with a chamois or an absorbing cloth Immediately dry the drive chain and lubricate it to prevent it from rusting Use a chrome polish to shine chrome aluminum and stainless steel parts MOTORCYCLE CARE AND STORAGE 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all meta
57. f 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 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions t prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled t prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down Itcuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure If a malfunction is noted have a Yamaha dealer
58. f the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit 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 INSTRUMENT AND CONTROL FUNCTIONS cuit See page 3 8 for a detailed expla nation of the function of this indicator light and on how to set it EAU38610 Immobilizer system indicator light 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 cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled NOTE This model is also equipped with a self diagnosis device for the immobilizer system If the immobilizer system is de fective the indicator light will start flash ing a pattern and the odometer tripmeter will display a 2
59. ght bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down EWA10790 4 Place a new headlight bulb into po sition and then secure it with the bulb holder ECA10650 CAUTION Take care not to damage the follow ing parts 6 34 e Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner e 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 PERIODIC MAINTENANCE AND MINOR REPAIR Connect the headlight coupler y 7 EAU24180 i _ EAU24202 Install the headlight bulb cover by Tail brake light Replacing a turn signal light turning it clockwise This model is equipped with an LED bulb Have a Yamaha dealer adjust the type of tail brake light 1 Remove the turn signal light lens headlight beam if necessary If the tail brake light does not come on by removing the screw have a Yamaha dealer check it 1 Screw Go 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new b
60. his period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17091 0 1000 km 0 600 mi Avoid prolonged operation above 6900 r min 1000 1600 km 600 1000 mi Avoid prolonged operation above 8300 r min 5 3 ECA10301 CAUTION After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10310 CAUTION Keep the engine speed out of the tachometer red zone e If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking stop the engine and then remove the key from the main switch Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 5 e Do not park on a slope or on soft EWA10310 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 EAU17240 Safety is an obligation of the owner Pe riodic inspection adjustment and lubri cation will keep your vehicle in the safest and most efficient condition pos sible The most important points of in spection adjustment and
61. hometer 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 activa tion This function allows you to select the engine speed at which the indi cator light will be activated Shift timing indicator light deactiva tion This function allows you to select the engine speed at which the indi cator light will be deactivated Shift timing indicator light bright ness This function allows you to adjust the brightness of the indicator light to suit your preference NOTE 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 multi function meter displays and tachometer 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to ON and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The control mode changes to the shift timing indicator light activity function To set the shift timing indicator light ac tivity function 1 Push the RESET button to select one of the following indicator light ac
62. however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom 3 1 mended to use either standard key and keep the code re regis tering key in a safe place Do not submerse any key in wa ter Do not expose any key to exces sively high temperatures Do not place any key close to magnets this includes but not limited to products such as speakers etc Do not place heavy items on any key Do not grind any key or alter its shape Do not disassemble the plastic part of any key Do not put two keys of any im mobilizer system on the same key ring Keep the standard keys as well as keys of other immobilizer systems away from this vehi cle s code re registering key Keep other immobilizer system keys away from the main switch as they may cause signal inter ference INSTRUMENT AND CONTROL FUNCTIONS EAU10471 Main switch steering lock The main switch steering lock controls the ignition and lighting systems and is used to lock the steering NOTE Be sure to use the standard key black bow for regular use of the vehicle To minimize the risk of losing the code re registering key red bow keep it in a safe place and only use it for code re registering EAU10550 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light
63. hrottle grip and cable 6 25 Checking and lubricating the brake and clutch levers 6 26 Checking and lubricating the sidestand s ssienereirenrennn 6 26 Lubricating the swingarm E T 6 27 Checking the front fork 6 27 Checking the steering 4 6 28 Checking the wheel bearings 6 28 Batlery 2ictin atria 6 29 Replacing the fuses 2 6 30 Replacing a headlight bulb 6 32 Tail brake light o oo 6 35 Replacing a turn signal light DUD ecard irate eee ae 6 35 Replacing the license plate light DUID AAE ETE E E E ET 6 36 Replacing an auxiliary light bulb 6 36 Supporting the motorcycle 6 37 Front wheel assisen 6 38 Rear wheel cessceessseeeeseees 6 40 Troubleshooting seee 6 41 Troubleshooting charts s es 6 42 MOTORCYCLE CARE AND STORAGE corners 7 1 Caferi eind aa E ae 7 1 Stora gen is teenie Naon 7 3 SPECIFICATIONS 0 eee 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 TABLE OF CONTENTS A SAFETY INFORMATION EAU10281 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EV ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTOR CYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON A
64. ing a speedometer which shows the riding speed a tachometer which shows engine speed an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero e 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 tim ing indicator light control mode NOTE e Be sure to turn the key to ON be fore using the SELECT and RE SET buttons 3 8 e For the U K only To switch the speedometer and odometer trip meter 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 ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit ECA10031 CAUTION Do not operate the engine in the ta chometer red zone Red zone 13750 r min and above Clock mode AZO o 77 rr a Tam Wt tS 1 Clock Turn the key to ON To set the clock 1 Push the SELECT button and RESET button t
65. ing for oil leakage If oil is leaking im mediately 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 13 Turn the engine off and then check the oil level and correct it if necessary Insert the projection into the slot and slide the cowling into its origi nal position 14 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Slot 2 Projection 15 Install and tighten the quick fasten er screws and then install the bolt EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU34011 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE e The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in an incorrect reading 2 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 6 12
66. ing on a slope or during sudden acceleration or deceleration but this is not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til 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 EAU11361 Fuel level warning light m 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 and then go off have a Yamaha dealer check the elec trical circuit 3 4 NOTE This model is also equipped with a self diagnosis device for the fuel level de tection 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 and then go off for 3 0 seconds If this occurs have a Yamaha dealer check the vehicle EAU11422 Coolant temperature warning light po This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The
67. ingarm in direction b and then push the rear wheel forward PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment 1 Axle nut 2 Drive chain slack adjusting bolt 3 Locknut 4 Alignment marks ECA10570 CAUTION Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the locknuts then the axle nut to their specified torques Tightening torques Locknut 16 Nm 1 6 m kgf 11 ft lbf Axle nut 150 Nm 15 0 m kgf 110 ft Ibf 6 24 EAU23022 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows ECA10581 CAUTION The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush 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
68. k on the front fork cap as shown in illustration A turn the adjusting bolt in direction b until the alignment marks match b If the alignment mark on the ad justing bolt is positioned before the alignment mark on the front fork cap as shown in illustration B turn the adjusting bolt in direction b until the alignment marks match 1 Spring preload adjusting bolt 2 Alignment marks To set the standard position turn the adjusting bolt 3 complete turns in direction b making sure the alignment marks match 1 Spring preload adjusting bolt 2 Alignment marks To set the standard position turn the adjusting bolt 2 complete turns in direction b making sure the alignment marks match 1 Spring preload adjusting bolt 2 Alignment marks 3 21 INSTRUMENT AND CONTROL FUNCTIONS 1 Spring preload adjusting bolt 2 Alignment marks To increase the spring preload and thereby hardening it turn the ad justing bolt in direction a from the standard position making sure to turn the bolt complete turns so that the alignment marks match To decrease the spring preload and thereby softening it turn the adjusting bolt in direction b from the standard position making sure to turn the bolt complete turns so that the alignment marks match Spring preload setting Minimum soft 11 complete turns in direction b from the standard position Standard position See explanations above Maxim
69. kcase oe that the O ring is properly seated 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter wrench 2 Engine oil filter cartridge 6 10 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf 10 Install the engine oil drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf PERIODIC MAINTENANCE AND MINOR REPAIR 11 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 replace ment 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 e In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 6 11 12 Start the engine and then let it idle for several minutes while check
70. l including chrome and nickel plat ed surfaces Use spray oil as a universal clean er to remove any remaining dirt Touch up minor paint damage caused by stones etc Wax all painted surfaces Let the motorcycle dry completely before storing or covering it EWA11130 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior NOTE Consult a Yamaha dealer for advice on what products to use ECA10800 CAUTION e Apply spray oil and wax spar ingly 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 7 3 EAU26201 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust e To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals a
71. l and oil filter cartridge 6 8 Engine stop switch 3 14 Engine trouble warning light we 3 7 EXUP system uu eee ce eeeeeeeeeeees 3 27 F Front and rear brake pads checking 6 21 Front fork adjusting eee 3 21 Front fork checking 6 27 Fuel is Fuel consumption tips for reducing 5 3 Fuel level warning light 3 4 Fuel tank breather overflow hose 3 18 Fuel tank cap Fuses replacing Handlebar SWitches ccccccssseeeeeees 3 14 Hazard SWItCN ccccccccccesesstteeeeeeeeees 3 15 Headlight bulb replacing 6 32 Helmet holders High beam indicator light 3 4 Horn Swithin roenan 3 14 l Identification NUMbETS cccceeeeeeeee 9 1 Ignition circuit cut off system 3 28 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 0 3 3 K Key identification numbet c 0e 9 1 L License plate light bulb replacing 6 36 Luggage strap holders M Main switch steering lock 3 2 Model label cece eee eee eeneeseeeeees 9 2 Multi function meter unit 3 8 N Neutral indicator light ee 3 4 0 Oil level warning light 0 ee 3 4 Panels removing and installing 6 6 Parking cece eeeeeeeeeeeeeeneeeees Part locations es Pass switehisi2 22i faseseintdccssberaec Periodic maintenance and lubrication Chart
72. mber is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area CONSUMER INFORMATION EAU33941 Model label 1 Muffler bracket cover 2 Muffler bracket 1 Model label The model label is affixed to the frame under the passenger seat See page 3 19 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer EWA12371 A WARNING Do not touch either muffler bracket located under the muffler bracket covers until the exhaust system has cooled 9 2 A Air filter element replacing 0 6 14 Anti theft alarm optional 3 13 Auxiliary light bulb replacing 6 36 B Battery isdeginta ei 6 29 Brake and clutch levers checking and lubricating Brake fluid changing a Brake fluid level checking 00 Brake lever vec cscacsecaveseeaseteccsacnsesseiteedece Brake pedal eeeeseeceseesseesseeeseees Cc Catalytic converter Clutch lever cece eeeeeeeeeeeeneeeeees Clutch lever free play adjusting Coolant aaa haa a Coolant temperature warning light D Dimmer SWitCH oo eee eres 3 14 Drive chain cleaning and lubricating 6 24 Drive chain slack eee 6 23 E Engine break in eee eeeeeeeeeeeeeeeeee 5 3 Engine idling speed eee 6 16 Engine oi
73. mediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13390 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 de signed to use premium unleaded gaso line with a research octane number of 95 or higher If Knocking or pinging oc curs use a gasoline of a different aia brand Use of unleaded fuel will extend Fuel tank breather overflow spark plug life and reduce maintenance NOSE costs 1 Fuel tank breather overflow hose Before operating the motorcycle Check the fuel tank breather over flow hose connection Check the fuel tank breather over flow hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather overflow hose is not blocked and clean it if necessary Make sure that the end of the fuel tank breather overflow hose is po sitioned outside of the cowling 3 18 EAU13431 Catalytic converter This model is equipped with a catalytic converter in the exhaust system The exhaust system is ho
74. nd with the total weight of rider passenger car go and accessories approved for this model EWA10500 6 17 Tire air pressure measured on cold tires 0 90 kg 0 198 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm 90 200 kg 198 441 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Maximum load 200 kg 441 Ib Total weight of rider passenger car go and accessories Because loading has an enormous impact on the handling braking performance and safety characteris tics of your motorcycle you should keep the following precautions in mind EWA11020 PERIODIC MAINTENANCE AND MINOR REPAIR NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride Tire inspection 1 Tire sidewall 2 Tire tread depth
75. ndlebar switches page 3 14 Main switch steering lock page 3 2 Multi function meter unit page 3 8 Right handlebar switches page 3 14 Throttle grip page 6 16 Brake lever page 3 16 NOOR WD 2 3 EAU10972 Immobilizer system WV 1 Code re registering key red bow 2 Standard keys black bow This vehicle is equipped with an immo bilizer system to help prevent theft by re registering codes in the standard keys This system consists of the fol lowing a code re registering key with a red bow two standard keys with a black bow that can be re registered with new codes a transponder which is installed in the code re registering key an immobilizer unit an ECU INSTRUMENT AND CONTROL FUNCTIONS an immobilizer system indicator light See page 3 3 The key with the red bow is used to reg ister codes in each standard key Since re registering is a difficult process take the vehicle along with all three keys to a Yamaha dealer to have them re reg istered Do not use the key with the red bow for driving It should only be used for re registering the standard keys Al ways use a standard key for driving ECA11820 CAUTION e DO NOT LOSE THE CODE RE REGISTERING KEY CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle
76. nt of the rear wheel or under Front wheel each side by removing the bolt and each side of the swingarm Bakes nut To remove the front wheel 4 Remove the brake caliper on each EWA10820 side by removing the bolts It is advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the wheel axle pinch bolts the axle bolt and then the brake caliper bolts 1 2 Bolt and nut 3 Brake caliper bolt 4 Brake caliper 5 Axle bolt 5 Remove the axle bolt push the wheel axle out from the left side and then remove the wheel 1 Front wheel axle pinch bolt 2 Lift the front wheel off the ground according to the procedure on page 6 37 6 38 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 EAU33932 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 4 Install the brake calipers by install ing the bolts and then tightening them to the specified torque PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs Tightening torque Brake caliper bolt 35 Nm 3 5 m kgf 25 f
77. nto the socket 6 Install the socket together with the bulb by pushing it in 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 fas tener 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 6 37 EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der 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 motor cycle stand is not available by placing PERIODIC MAINTENANCE AND MINOR REPAIR a jack either under each side of the 5AU24380 3 Remove the brake hose holder on frame in fro
78. ogether for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours INSTRUMENT AND CONTROL FUNCTIONS 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 Odometer tripmeters fuel reserve tripme ter stopwatch Push the SELECT button to switch the display between the odometer mode ODO the tripmeter modes TRIP A and TRIP B and the stop watch mode in the following order TRIP A gt TRIP B gt ODO gt Stop watch gt TRIP A 3 9 If the fuel level warning light comes on see page 3 3 the odometer display will automatically change to the fuel re serve 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 odome ter and stopwatch modes in the follow ing order F TRIP Stopwatch gt TRIP A gt TRIP B gt ODO gt F TRIP To reset a tripmeter select it by push ing 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
79. ollow if loading cargo or adding acces sories to your motorcycle A SAFETY INFORMATION Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Maximum load 200 kg 441 Ib When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently e Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories e Never install accesso
80. oolant 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 8 1 Fuel Recommended fuel Premium unleaded gasoline only 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 Fuel injection Manufacturer DENSO Model quantity 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 2nd 33 16 2 063 3rd 37 21 1 762 Ath 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 PIRELLI DIABLO CORSA H Rear tire Type Tubeless Size 190 50 ZR17M C 73W Manufacturer model PIRELLI DIABLO CORSA Loading Maximum load 200 kg 441 Ib Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198
81. ose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the vehicle so that there is no danger of it falling over EWA10750 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering 6 28 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU23441 1 Negative battery terminal 2 Battery 3 Positive battery terminal This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 e Electrolyte is poisonous and dangerous since it contains sul furic a
82. 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 6 8 EAU34003 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 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 in correct reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located in the bottom right side of the crankcase NOTE The engine oil should be between the minimum and maximum level marks 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 fol lows a Fit the rubber protector on the special wrench NOTE The special wrench and rubber protec
83. re stored Long term Before storing your motorcycle for sev eral 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 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning EWA10950 MOTORCYCLE CARE AND STORAGE Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffl
84. ries or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance 1 3 limit suspension travel steering travel or control operation or ob scure lights or reflectors e Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles e Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended e Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas GASOLINE IS HIGHLY FLAMMA
85. s to check for proper e It is advisable to have a Yamaha 5 Turn the drive chain slack adjust fork operation dealer service the wheel ing bolts fully in direction a and e Securely support the motor push the wheel forward cycle so that there is no danger 6 Remove the drive chain from the of it falling over rear sprocket 1 Loosen the axle nut NOTE e f the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket e The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out 1 i nut and then remove the wheel 2 Drive chain slack adjusting bolt 3 Locknut 4 5 Brake caliper Brake caliper bracket 6 40 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 cal iper bracket by inserting the wheel axle from the left hand side NOTE e Be sure to insert the retainer on the brake caliper bracket into the slot in the swingarm PERIODIC MAINTENANCE AND MINOR REPAIR Make sure that there is enough space between the brake pads be fore installing the wheel 1 Retainer 2 Slot 2 Install the drive chain onto the rear sprocket 3 Inst
86. sed by transpon der interference If this error code ap pears try the following INSTRUMENT AND CONTROL FUNCTIONS 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the right display indicates any error codes note the code number and then have a Yamaha dealer check the vehi cle 3 11 ECA11590 CAUTION If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage Display brightness and shift timing indicator light control mode 1 Display brightness 2 Shift timing indicator light activation deacti vation 3 Shift timing indicator light This mode cycles through five control functions allowing you to make the fol lowing settings in the order listed be low INSTRUMENT AND CONTROL FUNCTIONS Display brightness This function allows you to adjust the brightness of the displays and tac
87. t Ibf 5 Install the brake hose holders 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 Axle bolt 91 Nm 9 1 m kgf 66 ft lbf 7 Tighten wheel axle pinch bolt B and then tighten pinch bolt A to the specified torque 6 39 Vi TAU 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 8 Retighten pinch bolt B to the spec ified torque Tightening torque Wheel axle pinch bolt 26 Nm 2 6 m kgf 19 ft Ibf 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 spec ified torque PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 2 Lift the rear wheel off the ground Tightening torque NGA Bae ach bolt Rear wheel according to the procedure on 26 Nm 2 6 m kgf 19 ft Ibf Sieh page 6 37 To remove the rear wheel 3 Remove the axle nut 12 While applying the front brake ewaiezo 4 Loosen the locknut on each side of push down hard on the handlebar P AN the swingarm several time
88. t after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work EWA10860 ECA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages e Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter e 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 INSTRUMENT AND CONTROL FUNCTIONS EAU33860 Seats Rider seat 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 po sition and then install the bolts 3 19 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 2 n BS SE x N gt 1 Passenger seat lock 2 Unlock INSTRUMENT AND CONTROL FUNCTIONS 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward 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
89. t exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary INSTRUMENT AND CONTROL FUNCTIONS EAU39270 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing knob and a rebound damping force adjusting screw It is also equipped with a compression damping force adjusting bolt for fast compression damping and a compression damping force ad justing screw for slow compression damping ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 23 Spring preload 1 Spring preload adjusting knob To decrease the spring preload and thereby soften the suspension turn the adjusting knob in direction a To in crease the spring preload and thereby harden the suspension turn the adjust ing knob in direction b Spring preload setting Minimum soft O turn s in direction b Standard 6 turn s in direction b Maximum hard 20 turn s in direction b With the adjusting knob fully turned in direction a INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Adjust the rebound damping force as follows 1 Remov
90. t is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle EWA11150 4 1 PRE OPERATION CHECKS Pre operation check list CHECKS EAU15603 e Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage Engine oil e Check oil level in engine e If necessary add recommended oil to specified level e Check vehicle for oil leakage Coolant e Check coolant level in reservoir e If necessary add recommended coolant to specified level e Check cooling system for leakage Front brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear e Replace if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage Rear brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear e Replace if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to spe
91. t use the parking position for an extended length of time other wise the battery may discharge 3 3 EAU11003 Indicator and warning lights Left turn signal indicator light lt a Neutral indicator light N High beam indicator light 20 Right turn signal indicator light 5 gt Fuel level warning light W Oil level warning light 9 amp 7 Coolant temperature warning light E Shift timing indicator light Engine trouble warning light 5 0 lmmobilizer system indicator light gt OMNOOARWD EAU11030 Turn signal indicator lights lt 4 and Tj D The corresponding indicator light flash es when the turn signal switch is pushed to the left or right INSTRUMENT AND CONTROL FUNCTIONS EAU11060 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position EAU11080 High beam indicator light o This indicator light comes on when the high beam of the headlight is switched on 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 cir cuit NOTE Even if the oil level is sufficient the warning light may flicker when rid
92. the shift timing indicator light will remain deactivated Push the RESET button to select the desired engine speed for deac tivating the indicator light Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light bright ness function EAU12331 Anti theft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information activation function To adjust the shift timing indicator light NOTE brightness 1 Push the RESET button to select the desired indicator light bright ness level 2 Push the SELECT button to con firm the selected indicator light brightness level The right display will return to the odometer or trip meter mode The shift timing indicator light de activation function can be set be tween 7000 r min and 15000 r min From 7000 r min to 12000 r min the indicator light can be set in in crements of 500 r min From 12000 r min to 15000 r min the in dicator light can be set in incre ments of 200 r min 3 13 INSTRUMENT AND CONTROL FUNCTIONS Handlebar switches Left aBkWOND Pass switch PASS Dimmer switch 20 20 Turn signal switch lt a c gt Horn switch pes Hazard switch A EAU12344 Right 1 Engine stop switch O R 2 Start switch
93. time with the en gine not running otherwise the bat tery may discharge INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12820 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 28 3 15 Shift pedal 1 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle INSTRUMENT AND CONTROL FUNCTIONS EAU33850 Brake lever 1 Brake lever 2 Brake lever position adjusting knob 3 Distance between brake lever and handlebar grip 4 fA mark The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting knob To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting knob while holding the lever pushed away from the handlebar grip When the de sired position is obtained be sure to set it by aligning a groove on the adjusting knob with the
94. tivity settings 3 12 e The indicator light will stay on when activated This setting is selected when the indicator light stays on e The indicator light will flash when activated This setting is selected when the indicator light flashes four times per second The indicator light is deacti vated 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 con firm the selected indicator light ac tivity The control mode changes to the shift timing indicator light acti vation function To set the shift timing indicator light ac tivation 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 indica tor light can be set in increments of 200 r min 1 Push the RESET button to select the desired engine speed for acti vating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light deactiva tion function To set the shift timing indicator light de INSTRUMENT AND CONTROL FUNCTIONS e Be sure to set the deactivation function to a higher engine speed than for the activation function otherwise
95. uel level warning light 5 1 e Coolant temperature warning light e Shift timing indicator light e Engine trouble warning light e Immobilizer system indicator light If a warning or indicator light does not go off see page 3 3 for the corre sponding warning and indicator light circuit check 2 Shift the transmission into the neu tral position NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 3 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre OPERATION AND IMPORTANT RIDING POINTS serve the battery Do not crank the en gine more than 10 seconds on any one attempt ECA11040 CAUTION For maximum engine life never ac celerate hard when the engine is cold NOTE The engine is warm when it quickly re sponds to the throttle EAU16671 Shifting 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 il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly
96. ulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA11190 CAUTION Do not overtighten the screw other wise the lens may break 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 1 EAU33910 Replacing the license plate naa d area Replacing an auxiliary light light bulb 4 Insert a new bulb into the socket bulb 1 Remove the license plate light unit 5 Install the socket together with the This model is equipped with two auxil by removing the screws bulb by pushing it in iary lights If an auxiliary light bulb burns 6 Install the license plate light unit by OUt replace it as follows installing the screws 1 Remove panel A if replacing the left auxiliary light bulb or panel C if replacing the right auxiliary light bulb See page 6 6 2 Remove the auxiliary light bulb cover by removing the quick fas tener NOTE ale Screw l l Remove the quick fastener by pushing 2 License plate light unit the center pin in with a screwdriver 2 Remove the socket together with then pulling the fastener out the bulb by pulling it out y 1 Quick fastener 1 License plate light bulb 2 Auxiliary light bulb cover 6 36 3 Remove the socket together with the bulb by pulling it out 1 Auxiliary light bulb socket 4 Remove the defective bulb by pull ing it out 1 Auxiliary light bulb 5 Insert a new bulb i
97. um hard 2 complete turns in direction a from the standard position Rebound damping force Y Ae 1 Rebound damping force adjusting bolt To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting bolt on each fork leg in direction a To decrease the re bound damping force and thereby soft en the rebound damping turn the adjusting bolt on each fork leg in direc tion b 3 22 Rebound damping setting Minimum soft 17 click s in direction b Standard 12 click s in direction b Maximum hard 1 click s in direction b With the adjusting bolt fully turned in direction a Compression damping force 1 Compression damping force adjusting bolt To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting bolt on each fork leg 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 bolt fully turned in direction a ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings NOTE Although the total number of clicks of a damping force adjusting mechanism may no
98. veal the condition of the engine The porcelain insulator around the cen ter 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 en gine 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 deal er check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Specified spark plug NGK CR9EK PERIODIC MAINTENANCE AND MINOR REPAIR Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Jt 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 0 ft lbf NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible ECA10840 CAUTION Do not use any tools to remove or in stall the spark plug cap otherwise the ignition coil coupler may get damaged The spark
99. ying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar with the motorcycle and all of its controls Many accidents have been caused by error of the motorcycle opera tor A typical error made by the op erator is veering wide on a turn due to EXCESSIVE SPEED or un dercornering insufficient lean an gle for the speed e Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions e Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs A SAFETY INFORMATION This motorcycle is designed for on road use only It is not suitable for off road use Protective apparel The majority of fatalities from motor cycle accidents are the result of head injuries The use of a safety
100. yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first IMPORTANT MANUAL INFORMATION EAU10151 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS A INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the A WARNING motorcycle operator a bystander or a person inspecting or repairing the motor cycle A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer CAUTION NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e 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 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY

Yamaha Motorcycle YZF-R1S User's Manual

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