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Star Motorcycles yamaha Offroad Vehicle User Manual

1. EAU23211 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it EWA10740 Recommended lubricant Lithium soap based grease all pur pose grease 6 28 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 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 loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in th
2. 42 psi 5VY 21668 00 J AWARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 Left view ANoOaRKRWD Front fork spring preload adjusting bolt page 3 14 Front fork compression damping force adjusting screw page 3 14 Air filter element page 6 15 Main fuse page 6 31 Fuel injection system fuse page 6 31 Storage compartment page 3 14 Passenger seat lock page 3 12 Shock absorber assembly spring preload adjusting ring page 3 16 DESCRIPTION EAU10410 9 Shock absorber assembly rebound damping force adjusting screw page 3 16 10 Shift pedal page 3 9 11 Engine oil drain bolt page 6 10 12 Engine oil filter cartridge page 6 10 DESCRIPTION Right view ANOaRWD Owner s tool kit page 6 1 Rider seat lock lever page 3 12 Fuse box page 6 31 Battery page 6 30 Rear brake fluid reservoir page 6 23 Engine oil filler cap page 6 10 Front brake fluid reservoir page 6 23 Front fork rebound damping force adjusting screw page 3 14 2 2 9 Engine oil level check window page 6 10 10 Brake pedal page 3 10 11 Coolant reservoir page 6 13 12 Luggage strap holder page 3 18 EAU10420 Controls and instruments NOOR WD Clutch lever page 3 9
3. Pre operation check list R Rear brake light switch adjusting 6 22 S Safety defects reporting 0 ee 9 3 Safety information eee 1 1 Seats 3 12 Shifting 5 2 Shift Pedal oo ce ceeeeseessteseseseeeeeeeeees 3 9 Shock absorber assembly adjusting 3 16 SideOStaN ccececiaseseereennececrecaeaneedts 3 18 Spark plugs Checking cece 6 9 Specifications 8 4 Starting the engine 5 1 Start SWIC oo e eee eeeeeeee tee eeeeeee 3 8 Steering Checking c ees 6 29 Storage 5 Storage compartment ee 3 14 T Tail orake light bulb replacing 6 34 Throttle cable free play checking 6 17 Throttle grip and cable checking INDEX Troubleshooting e cece eee Troubleshooting charts Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 35 Turn signal switch seses 3 8 V Valve clearance oo eee cece terres 6 17 Vehicle identification number 0 9 1 W Warranty extended 9 9 Warranty limited a n 9 7 Wheel bearings checking 6 30 Wheel front 0 0 eeeesseeesceesseesseeeesees 6 36 Wheel rear 00 cee eeseeeseeeseeesseessaeeesees 6 38 Wheels oo ee cece eeeeeeeeeeseeeseeeneeeaes 6 20 See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2006 09 0 8x1 CR E
4. button and RESET button together for at least two seconds 3 When the hour digits start flashing push the RESET button to set the hours 3 5 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes LoF fr p 25 TRIPA RESET SELECT 1 Odometer tripmeter fuel reserve tripmeter Push the SELECT button to switch the display between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in the following order TRIP A gt TRIP B ODO gt TRIP A When the fuel amount in the fuel tank decreases to 3 4 L 0 90 US gal 0 75 Imp gal the left segment of the fuel meter will start flashing and the odom a eter display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter and odometer modes in the following order F TRIP gt TRIP A gt TRIP B ODO 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
5. e Headlight bulb 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary 1 2 EAU24112 Replacing the tail brake light bulb Remove the passenger seat See page 3 12 Remove the socket together with the bulb by turning it counter clockwise 1 Tail brake light bulb socket 3 6 6 34 Remove the defective bulb by pushing it in and turning it counter clockwise Insert a new bulb into the socket push it in and then turn it clock wise until it stops Install the socket together with the bulb by turning it clockwise Install the passenger seat PERIODIC MAINTENANCE AND MINOR REPAIR EAU43000 ECA11190 Replacing a turn signal light CAUTION bulb Do not overtighten the screw other 1 Remove the turn signal light unit wise the lens may break by removing the screw eal oer 1 Turn signal light unit 2 Screw 1 Turn signal light bulb socket 3 Remove the defective bulb by pull ing it out 2 Remove the socket together with the bulb by turning it counter clockwise 1 Turn signal light bulb 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light unit by installing the screw 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 Replacing the license pla
6. 1 click s in direction b With the adjusting screw fully turned in direction a Compression damping force 1 Compression damping force adjusting screw The compression damping force is ad justed on the left front fork leg only To increase the compression damping 3 15 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 NOTE Be sure to perform this adjustment on the left front fork leg Compression damping setting Minimum soft 26 click s in direction b Standard 5 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw 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 not 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 EAU39341 Adjusting the shock absorber assembly This shock
7. 9 4 CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of Mileage Servicing dealer Remarks interval service name and address 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or 42 months 32000 mi 49000 km or 48 months CONSUMER INFORMATION Maintenance interval Mileage Servicing dealer name and address Remarks 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months 9 6 CONSUMER INFORMATION YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants that new Yamaha motorcycles will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn sign
8. el C See page 6 8 Remove the reservoir cap add coolant to the maximum level mark and then install the reservoir cap 6 CAUTION PERIODIC MAINTENANCE AND MINOR REPAIR 1 Coolant reservoir cap Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt ECA10471 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 cooling 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 5 Install the panel NOTE e The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 40 for further instructions EAU33030 Changing the coolant Never attempt to remove the radiator cap when the engine is hot EWA10380 6 14 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 EAU40051 Replacing
9. signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems INSTRUMENT AND CONTROL FUNCTIONS EAU13441 Catalytic converter This vehicle is equipped with catalytic converters in the exhaust system EWA10860 A WARNING The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work 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 3 12 EAU39322 Seats Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then
10. have a Yamaha dealer check the electrical system 6 32 PERIODIC MAINTENANCE AND MINOR REPAIR 23930 6 Install the battery cover and then hook the battery band onto the holder EAU Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 1 Headlight coupler 2 Headlight bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 6 33 1 Headlight bulb holder 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 EWA10790 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 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 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
11. tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Shift up points 1st 2nd 20 km h 12 5 mi h 2nd gt 3rd 30 km h 18 8 mi h 3rd 4th 40 km h 25 0 mi h 4th gt 5th 50 km h 31 3 mi h 5th gt 6th 60 km h 37 5 mi h Shift down points 6th gt 5th 25 km h 15 5 mi h 5th gt 4th 25 km h 15 5 mi h 4th gt 3rd 25 km h 15 5 mi h 3rd 2nd 25 km h 15 5 mi h 2nd gt 1st 25 km h 15 5 mi h 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 this 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 6000 r min 1000 1600 km 600 1000 mi Avoid prolonged operation above 7200 r min ECA10301 CAUTION After 1000 km 600 mi of operation the engine oil must be changed
12. 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 PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torques Locknut 16 Nm 1 6 m kgf 11 ft lbf Axle nut 150 Nm 15 0 m kgf 110 ft Ibf 6 25 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 dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant PERIODIC MAINTENANCE AND MINOR REPAIR 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 EAU23091 Checking and lubri
13. Left handlebar switches page 3 8 Main switch steering lock page 3 1 Multi function meter unit page 3 4 Right handlebar switches page 3 8 Throttle grip page 6 17 Brake lever page 3 10 2 3 DESCRIPTION EAU10430 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch steering lock The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions are described below EAU26900 ON All electrical circuits are supplied with power and the meter lighting taillight license plate light and position 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 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 3 1 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
14. 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 130 0 mm 5 12 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper SPECIFICATIONS Wheel travel 130 0 mm 5 12 in Electrical system Ignition system Transistorized coil ignition digital Charging system AC magneto Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 2 Tail brake light 12 V 5 0 W 21 0W x 1 Front turn signal position light 12 V 21 W5 0W x2 Rear turn signal light 12V 21 0Wx2 License plate light 12V 50Wx1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 50 0A Headlight fuse 20 0A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 10 0Ax2 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 fr
15. 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 41 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 CAUTION Some models are equipped with matte colored finished parts Be sure to consult a Yamaha dealer for advice on what products to use be fore cleaning the vehicle Using a brush harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface Wax also should not be applied to any matte colored fin ished parts EAU26011 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 electrical couplers and connectors inc
16. 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 e 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 5 4 EAU17212 Parking When parking stop the engine and then remove the key from the main switch e 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 e Do not park ona slope or on soft ground otherwise the vehicle may overturn EWA10310 ECA10380 CAUTION Never park in an area where there are fire hazards such as grass or other flammable materials EAU17231 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 motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable EWA10320 A WARNING If you are not familiar with mainte nance work have a Yamaha dealer do it for you PERIODIC MAINTENANCE AND MINOR REPAIR 7301 EAU1 PERIODIC MAINTENA
17. gt YAMAHA EAU10041 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZS10W FZS10WC This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION EAU10131 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
18. in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 9 9 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service CONSUME
19. 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 NOTE The rear brake fluid reservoir is located behind panel C See page 6 8 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 23 e 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 e 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 cause PERIODIC MAINTENANCE AND MINOR REPAIR 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 ch
20. machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by a Yamaha motorcycle dealer Q Will the warranty be void or cancelled if do not operate or maintain my new PO PO motorcycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as described in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirem
21. of the new oil filter car tridge NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 6 11 PERIODIC MAINTENANCE AND MINOR REPAIR 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 1 O ring 1 Torque wrench e In order to prevent clutch slip NOTE Tightening torque page since the engine oil also Make sure that the O ring is properl Oil filter cartridge lubricates the clutch do not seated KARTET 17 Nm 1 7 m kgf 12 ft lbf mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high 6 Install the new oil filter cartridge 7 Install the engine oil drain bolt and with an oil filter wrench and then tighten it to the specified torque with a torque wrench then tighten it to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 6 12 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 Start the engi
22. 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 EAU11003 Indicator and warning lights Left turn signal indicator light lt a Right turn signal indicator light 5 gt Neutral indicator light N High beam indicator light 20 Engine trouble warning light 5 Oil level warning light Coolant temperature warning light E NOOR WD EAU11030 Turn signal indicator lights lt 4 and 13 D The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position INSTRUMENT AND CONTROL FUNCTIONS 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 riding on a slop
23. temperature does not go down stop the engine See page 6 40 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 40 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 4 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 If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit INSTRUMENT AND CONTROL FUNCTIONS EAU40172 Multi function meter unit 1 2 r ECN pig ma Nes 1 Coolant temperature display air intake tem perature display 2 Speedometer 3 Tachometer 4 Odometer tripmeter fuel reserve tripmeter 5 SELECT button 6 7 8 pR RESET button Clock Fuel meter EWA12421 Be sure to stop the vehicle before making any setting changes to the multi function meter unit The multi function meter unit is equipped with the following a speedometer which shows the riding speed 3 4 atachometer which shows engine speed an odometer which shows the to tal distance traveled two tripmeters which show the distance travel
24. 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 12 2 Remove panels A and B See page 6 8 3 Remove the cowling bolts and then pull the cowling off 1 Cowling 2 Bolt 4 Remove the fuel tank bolts PERIODIC MAINTENANCE AND MINOR REPAIR PRS D D 1 Bolt 5 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 EWA10410 Make sure that the fuel tank is well supported 6 15 e Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 6 Remove the air filter case cover by removing the screws ECA12880 CAUTION When removing the air filter case cover be careful not to allow foreign objects to drop into the air intake manifold 1 Screw 2 Air filter case cover 7 Pull the air filter element out PERIODIC MAINTENANCE AND MINOR REPAIR Ewari360 11 Place the cowling in the original PIQUCNGININGH position and then install the bolts e Before placing the fuel tank in 12 Install the panels the original position make sure 13 Install the rider seat that the fuel hoses are not dam aged If any fuel hose is da
25. the prior mode after refueling and traveling 5 km 3 mi INSTRUMENT AND CONTROL FUNCTIONS Fuel meter LoF Ce RESET SELECT 1 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display seg ments of the fuel meter disappear to wards E Empty as the fuel level decreases When only one segment is left near E refuel as soon as possible NOTE This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective the following cycle will be repeated until the malfunction is cor rected E Empty F Full and sym bol fs will flash eight times then go off for approximately 3 seconds If this oc curs have a Yamaha dealer check the electrical circuit 3 6 Coolant temperature mode 1 Lo E c bu fren koo a 00 CO 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 coolant tempera ture is displayed ECA10020 CAUTION Do not operate the engine if it is overheated INSTRUMENT AND CONTROL FUNCTIONS Air intake temperature mode s oe Eam MPI feo N0 RESET SELECT 1 Air in
26. turn it counterclockwise 1 Passenger seat lock 2 Unlock 2 Pull the passenger seat forward and then lift it up To install the passenger seat 1 Place the passenger seat in the original position and then push the rear of the seat down to lock it in place INSTRUMENT AND CONTROL FUNCTIONS NOTE Make sure that the seats are properly secured before riding 1 Rider seat lock lever 2 Remove the key To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place Rider seat To remove the rider seat 1 Remove the passenger seat 2 Push the rider seat lock lever lo cated under the back of the rider 1 seat to the right as shown and then pull the seat off SA 2 Z 1 Projection 2 Seat holder 2 Install the passenger seat 3 13 EAU14461 Storage compartment 1 Storage compartment The storage compartment is located under the passenger seat See page 3 12 Do not exceed the load limit of 3 kg 7 Ib for the storage com partment e Do not exceed the maximum load of 189 kg 417 Ib CAL 190 kg 419 Ib U49 for the ve hicle EWA10961 INSTRUMENT AND CONTROL FUNCTIONS EAU39332 Adjusting the front fork Each front fork leg is equipped with a spring preload adjusting bolt the right front fork leg is equipped with a re bound damp
27. 2 OPERATION AND IMPORTANT RIDING POINTS eee 5 1 Starting the engine eeee 5 1 Shifting chvcie advan 5 2 Engine break in ou eee 5 4 Parking aier ane aed 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit aseeseen 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication Chart ece 6 4 Removing and installing panels 6 8 Checking the spark plugs 6 9 Canister for California only 6 10 Engine oil and oil filter cartridge 6 10 Coolant seareiros ainn 6 13 Replacing the air filter element 6 15 Checking the throttle cable free jaN A E EE EEE EEEE denen 6 17 Valve clearance csseeeeeeeeeees 6 17 TIOS ienne A aA 6 17 Cast wheels nanna tan 6 20 Accessories and replacement paS enine ane egies 6 20 TABLE OF CONTENTS Adjusting the clutch lever free play diinon 6 21 Adjusting the rear brake light SWICK rsr 6 22 Checking the front and rear brake pads cccceeeeeereeeeeees 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Drive chain slack ene 6 24 Cleaning and lubricating the drive chain oo eee eeeeeeeneeeeeees 6 25 Checking and lubricating the Cables xsi eee eves 6 26 Checking and lubricating the throttle grip and cable 6 26 Checking and lubricating the brake an
28. 5 Nm 1 25 m kgf 9 0 ft Ibf PERIODIC MAINTENANCE AND MINOR REPAIR NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the 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 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 EAU19681 Canister for California only FUELTANK ATMOSPHERE pale Ri I O CHARCOAL THROTTLE BODY CANISTER This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Make sure that the canister breath er is not blocked and if necessary clean it o 6 10 EAU19871 Engine oil and oil filter car tridge The engine oil level should be checked before each ride In addition the oil must be chan
29. 8 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 CONSUMER INFORMATION PO PO gt O gt 0O WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the
30. HEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EV ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTOR CYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE MENTS IN THE OWNER S MAN UAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECH NICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECES SARY BY MECHANICAL CONDI TIONS Safe riding 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 e Ride where other motorists can see you Avoid riding in another motorist s blind spot e M
31. NCE PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEA SURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES 6 1 EAU17531 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 12 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs 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 PERIODIC MAINTENANCE AND MINOR REPAIR Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes EWA10340 6 2 Periodic maintenance chart for the emis
32. R INFORMATION We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be YAMAHA EXTENDED SERVICE happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 9 10 A Accessories and replacement parts 6 20 Air filter element replacing 6 15 B Battery 0 eecseccseeseeeseteecsseesseesseeseenes 6 30 Brake and clutch levers checking and lubricating 0 eee 6 27 Brake and shift pedals checking and lubricating 0 eee eee 6 27 Brake fluid changing eee 6 24 Brake fluid level checking 05 6 23 Brake lever is Brake pedal c Cables checking and lubricating Canister for California only CAMO AE E E E ETET Catalytic converter Centerstand and sidestand checking and lubricating 0 0 eeeee 6 28 Clutch lOVer cc ceeeseseeseeseseseseeeeseeees 3 9 Clutch lever free play adjusting 6 21 Colani ini soia p 6 13 Coolant temperature warning light 3 2 D Dimmer SWitCH ooo eee cece eee eee 3 8 Drive chain cleaning and lubricating 6 25 Drive chain sla
33. absorber assembly is equipped with a spring preload adjust ing ring and a rebound damping force adjusting screw ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload 1 Spring preload adjusting ring 2 Special wrench 3 Position indicator 3 16 To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE e Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber e Use the special wrench included in the owner s tool kit to make the ad justment Spring preload setting Minimum soft 1 Standard Maximum hard 7 INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force 1 Rebound damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b Rebound damping setting Minimum soft 12 click s in direction b Standard 8 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 cli
34. ains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If the coolant temperature warn ing light flickers or remains on after starting immediately stop the engine and then check the coolant level and the vehicle for coolant leakage If necessary add coolant and then check the warning light again e if the engine trouble warning light flashes or remains on after starting immediately stop the engine and have a Yamaha dealer check the cause ECA11130 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold NOTE The engine is warm when it quickly re sponds to the throttle 5 2 EAU16671 Shifting YS fs AK 4 i 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 raise it 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
35. als shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leasing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of busin
36. amaha dealer at the intervals specified in the periodic maintenance and lubrication chart 6 17 EAU21750 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 and with the total weight of rider passenger car go and accessories approved for this model EWA10500 PERIODIC MAINTENANCE AND MINOR REPAIR 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 90 189 kg 198 417 Ib CAL 90 190 kg 198 419 Ib U49 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 189 kg 417 Ib CAL 190 kg 419 Ib U49 Total weight of rider passenger car go and accessories Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack
37. and then install the screw PERIODIC MAINTENANCE AND MINOR REPAIR EAU19652 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 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 operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Specified spark plug NGK CR9EK 6 9 Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification F 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
38. any 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 Staying 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 A SAFETY INFORMATION due to EXCESSIVE SPEED or un dercornering insufficient lean an gle for the speed Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator 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
39. ark plug gaps or replace the spark plugs Remove the spark plugs i and check the electrodes gt Dry gt Have a Yamaha dealer check the vehicle N o start 4 Battery am he engine 1Umns over The battery is good quickly The engine does not start Operate the electric starter gt Have a Yamaha dealer Pal The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 6 40 EAU42500 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 Place a thick rag like a towel over the radiator cap and then slowly rotate the cap counterclockwise to the de tent to allow any residual pressure to escape When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap EWAT1040 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 Ee no leakage Add coolant See NOTE engine has cooled reservoir and radiator j The coolant level Start the engine If the engine overheats
40. art 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 e Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22792 To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive chain slack as shown Si COCE Drive chain slack 25 0 35 0 mm 0 98 1 38 in 5 Ifthe 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 swingarm in direction b and then push the rear wheel forward 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 Drive chain slack 6 24 1 Axle nut 2 Locknut 3 Drive chain slack adjusting bolt 4 Alignment marks
41. as 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 20 PRE OPERATION CHECKS EAU15592 The condition of a vehicle is the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure could have serious consequences Therefore it is very important in addition to a thorough visual 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 EAU15605 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 i
42. ate pedal pivoting points if necessary Brake and clutch levers e Make sure that operation is smooth e Lubricate lever pivoting points if necessary Centerstand sidestand e Make sure that operation is smooth e Lubricate pivots 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 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 EAU40190 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following c
43. cating 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 Yamaha Chain and Cable Lube or engine oil SAE 10W 30 EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions 6 26 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 r s a EAU23140 Checking and lubricating the iaa E A aioa Checking and lubricating the brake and shift pedals PE a brake and clutch levers Brake lever Clutch lever The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu The operation of the brake and clutch bricated if necessary levers should be checked before each ride and the lever pivots should be lu bricated if necessary 6 27 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended lubricant Lithium soap based grease all pur pose grease
44. ch 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 e The vehicle must be placed on the centerstand during this in spection e Ifa malfunction is noted have a Yamaha dealer check the sys tem before riding EWA10260 3 19 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 h
45. ck eens 6 24 E Engine break in c eee Engine oil and oil filter cartridge X Engine stop sWitch 0 cece Engine trouble warning light 0 EXUP system uu eee cee eeeeeeeees Front and rear brake pads checking 6 22 Front fork adjusting Front fork checking Puli tsar E T EENT T TT Fuel tank Cap siseesisessrireieierirrrirsnes Fuses replacing sseeeeeeerrerrernen H Handlebar switches 3 8 Hazard switch 3 9 Headlight bulb replacing 6 33 High beam indicator light 3 2 Horn SWitch nesrodan 3 8 l Identification NUM ETS eeeeeeee 9 1 Ignition circuit cut off system 3 19 Indicator and warning lights 0 3 2 K Key identification numbet cce 9 1 L Labels location Of cccccccssseeeeeeeees 1 5 License plate light bulb replacing 6 36 Luggage strap holders cceeeeee 3 18 M Main switch steering lock 0 ee 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control SYSIOM hana eas 6 3 Maintenance periodic 0 ceeeee 6 1 Maintenance record ccceeeeeeeeeees 9 5 Matte color caution 7 1 Model label 9 2 Multi function meter unit 3 4 N Neutral indicator light 3 2 Noise regulation o Oil level warning light ee 3 2 P Panels removing and installing 6 8 Parki geniai raida Part locations
46. cks of the rebound damping force adjusting mechanism may not exactly match the above specifications due to small differ ences in production the actual number of clicks always represents the entire adjusting range To obtain a precise ad justment it would be advisable to check the number of clicks of the rebound damping force adjusting mechanism and to modify the specifications as nec essary 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 that may result from improper handling e Do not tamper with or attempt to open the gas cylinder EWA10220 3 17 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 Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU15150 Luggage strap holders 1 Luggage strap holder There is a luggage strap holder on each passenger footrest INSTRUMENT AND CONTROL FUNCTIONS EAU41940 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 T
47. clutch switch which is part of the igni tion circuit cut off system See page 3 19 3 9 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 EAU26822 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 1 4 1 Brake lever 2 Brake lever position adjusting dial 3 A mark 4 Distance between brake lever and handlebar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the A mark on the brake lever INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13072 Fuel tank cap 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 3 10 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 Pu
48. cycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces MOTORCYCLE CARE AND STORAGE 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA11130 A WARNING Make sure that there is no oil or wax on the brakes or tires e 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 ECA10800 CAUTION e Apply spray oil and wax spar ingly and make sure to wipe off any excess e Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product e Avoid using abrasive polishing compounds as they will wear away the paint EAU26180 Storage Short term Always store your
49. d shift pedals 6 27 Checking and lubricating the brake and clutch levers 6 27 Checking and lubricating the centerstand and sidestand 6 28 Checking the front fork 6 28 Checking the steering 6 6 29 Checking the wheel bearings 6 30 Battery neioii pai iia a 6 30 Replacing the fuses 02 02 6 31 Replacing a headlight bulb 6 33 Replacing the tail brake light DUIDe ciesticshacaeliti hee iar 6 34 Replacing a turn signal light bulbin cette we A eae 6 35 TABLE OF CONTENTS Replacing the license plate light eTl O EAE E tet heen ee 6 36 Front wheel sssini 6 36 Rear wheel escceeseeeeeeeeereees 6 38 Troubleshooting seee 6 39 Troubleshooting charts 6 40 MOTORCYCLE CARE AND STORAGE 2st ev etd 7 1 Matte color Caution 2ccceee 7 1 Gale ceca T tee cee ee 7 1 Strage i sia aeaiee aS 7 3 SPECIFICATIONS 00000 8 1 CONSUMER INFORMATION 9 1 Identification numbers 006 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 0 00seeee 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ssesessssssevesssssseeeeeee 9 7 YAMAHA EXTENDED SERVICE CES cercsro dats drad tones 9 9 A SAFETY INFORMATION EAU10281 MOTORCYCLES ARE SINGLE TRACK VEHICLES T
50. e 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 3 2 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 EAU11423 Coolant temperature warning light p This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit ECA10020 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 Temperature is displayed OK Go ahead with riding 117 139 C 243 283 F gt A l 43 a Epo 73 cee WA reb m aA d Warning light comes on Temperature display flashes Stop the vehicle and allow it to idle until the coolant temperature goes down If the
51. e 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 29 PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and 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 EAU33650 Battery 1 Positive battery terminal 2 Negative battery terminal 3 Battery 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 e Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when EWA10760 6 30 working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 m
52. ed since they were last set to zero e a fuel reserve tripmeter which shows the distance traveled since the left segment of the fuel meter started flashing a clock a fuel meter a coolant temperature display an air intake temperature display a self diagnosis device an LCD and tachometer bright ness control mode NOTE e Be sure to turn the key to ON be fore using the SELECT and RE SET buttons e To switch the speedometer and odometer tripmeter displays be tween kilometers and miles press the SELECT button for at least one second INSTRUMENT AND CONTROL FUNCTIONS 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 12000 r min and above Clock LoF ae RESET SELECT 1 Clock 2 Speedometer The clock displays when the key is turned to ON In addition the clock can be displayed for 10 seconds by pushing the SELECT button when the main switch is in the OFF or LOCK position To set the clock 1 Turn the key to ON 2 Push the SELECT
53. ents to your satisfaction at the time of sale and upon your request at any later date 3 Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective 9 8 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding the warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you IF you are still not satisfied and require additional assistance please write to YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibil
54. ess WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty 9 7 EAU26663 Engine Displacement Period Under 50cc 6 000 km 3 750 miles or five years whichever occurs first 50cc to 169cc 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc and over 30 000 km 1
55. ff before 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 BLE e Always turn the engine off when refueling 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 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
56. ged 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 the center stand NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE The engine oil should be between the minimum and maximum level marks 1 Engine oil filler cap 2 Engine oil level check window 3 Maximum level mark 4 Minimum level mark 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off PERIODIC MAINTENANCE AND MINOR REPAIR 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase 1 Oil filter wrench 2 Oil filter cartridge NOTE An oil filter wrench is available at a 1 Engine oil drain bolt Yamaha dealer Go 5 Apply a thin coat of engine oil to the O ring
57. hart ROUTINE INITIAL ODOMETER READINGS EAU32183 600 mi 1 month 4000 mi 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Air filter element e Replace Every 24000 mi 37000 km Clutch e Check operation e Adjust or replace cable Ni Ni Front brake e Check operation fluid level and for fluid leakage e Replace brake pads if necessary Rear brake e Check operation fluid level and for fluid leakage e Replace brake pads if necessary Brake hoses e Check for cracks or damage Ni Ni e Replace Every 4 years Wheels e Check runout and for damage e Replace if necessary Ni Ni e Check tread depth and for dam age e Replace if necessary e Check air pressure e Correct if necessary Wheel bearings e Check bearings for smooth oper ation e Replace if necessary Swingarm pivot bearings e Check bearing assemblies for looseness ROUTINE INITIAL ODOMETER READINGS Be xxrry _ EE MAINTENANCE ANE MINOR RERAIR 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Drive chain e Chec
58. hat 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 accessories 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 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 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 A SAFETY INFORMATION Always turn the engine o
59. he EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor ECA15610 CAUTION The EXUP system has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine 3 18 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 of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system 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 laniti z it cut off fom pair it if it does not function proper gni ion circuli cut oif Syste ly The ignition circuit cut off system com prising the sidestand switch clut
60. ing force adjusting screw and the left front fork leg with a com pression damping force adjusting screw Always adjust the spring preload on both fork legs equally otherwise poor handling and loss of stability may result EWA14670 Spring preload 1 Spring preload adjusting bolt To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt 1 Current setting 2 Front fork cap bolt INSTRUMENT AND CONTROL FUNCTIONS Spring preload setting Minimum soft 8 Standard 5 5 Maximum hard 0 3 Rebound damping force 1 Moo a Z Zi EN 1 Rebound damping force adjusting screw The rebound damping force is adjusted on the right front fork leg only To in crease the rebound damping force and thereby harden the rebound damping turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b NOTE Be sure to perform this adjustment on the right front fork leg Rebound damping setting Minimum soft 26 click s in direction b Standard 18 click s in direction b Maximum hard
61. inutes 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 e KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 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 PERIODIC MAINTENANCE AND MINOR REPAIR battery tends to discharge more quickly If you do not have access to a Replacina the f EAUASOIG if the vehicle is equipped with optional sealed type MF battery charg ePiacing Mie JuUSesS electrical accessories er have a Yamaha dealer The main fuse the fuel injection system charge your battery fuse and the fuse box which contains the fuses for the individual circuits are located under the rider seat See page 3 12 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 1 Main fuse nected to the battery terminals 2 Fuse box ECA10630 3 Fuel injection system fuse CAUTION 4 Fuel injecti
62. investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http Awww safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov 9 3 CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct
63. ity of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty e In addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months 36 months or on certain models even 48 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows
64. k chain slack alignment and condition e Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 600 mi 1000 km and after washing the motorcycle or riding in the rain Steering bearings e Check bearing assemblies for looseness e Moderately repack with lithium soap based grease every 10000 mi 16000 km or 18 months Chassis fasteners e Check all chassis fitting and fas teners e Correct if necessary Brake and clutch le ver pivot shafts e Apply lithium soap based grease all purpose grease lightly Brake and shift ped al pivot shafts e Apply lithium soap based grease all purpose grease lightly Centerstand and sidestand pivots e Check operation e Apply lithium soap based grease all purpose grease lightly Sidestand switch e Check operation and replace if necessary Front fork e Check operation and for oil leak age e Replace if necessary 6 5 PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi No ITEM ROUTINE 1000 km 7000 km 13000 km 19000 km 25000 km 31000 km or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months Shock absorber as e Check operation and for oil leak 18 age V V V V V sembly i e Replace if necessary 19 Rear suspension e Check opera
65. luding 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 7 1 ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning ECA10770 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 e Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic e Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switches and lights breather hoses and vents For motorcycles equip
66. m aged do not start the engine but have a Yamaha dealer replace the hose otherwise fuel may 1 Air filter element leak 2 Air intake manifold e Make sure that the fuel hoses DS are properly connected and 8 Insert a new air filter element into routed and not pinched the air filter case amp e Be sure to place the fuel tank 10480 breather hose and the fuel tank CAUTION a overflow hose in the original po Make sure that the air filter ele sition 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 9 Install the air filter case cover by in stalling the screws 10 Place the fuel tank in the original position and then install the bolts 1 Fuel tank breather overflow hose 2 Original position paint mark 6 16 EAU21382 Checking the throttle cable free play eS 1 Throttle cable free play 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 Y
67. motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION Consult a Yamaha dealer for advice on Storing the motorcycle in a NOTE what products to use 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 To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 2 7 3 Follow all the instructions in the Care section of this chapter 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
68. n 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 specified level e Check hydraulic system for leakage 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 Brake and shift pedals e Make sure that operation is smooth e Lubric
69. ne and then let it idle for several minutes while checking it 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 10 Turn the engine off and then check the oil level and correct it if necessary PERIODIC MAINTENANCE AND MINOR REPAIR 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 EAU40041 To check the coolant level 1 Place the vehicle on the center stand NOTE 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 13 a Y al ine 6 1 Coolant reservoir 2 Maximum level mark 3 Minimum level mark 3 4 If the coolant is at or below the minimum level mark remove pan
70. new tire e The tires must be warmed up before a high speed run e Always adjust the tire air pres sure according to the operating conditions EAU21960 Cast 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 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 6 20 EAU22011 Accessories and replacement parts This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamaha Parts and Accessories are designed and test ed to be compatible with your vehi cle Please consider Genuine Yamaha Parts and Accessories be fore making a purchase U
71. ng 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 22 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 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 PERIODIC MAINTENANCE AND MINOR REPAIR Before riding check that the brake fluid is above the minimum
72. notice IMPORTANT MANUAL INFORMATION EAU10192 LABEL HERE o AFFIX DEALER _ IE FZS10W FZS10WC OWNER S MANUAL 2006 by Yamaha Motor Corporation U S A 1st edition September 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 20 54 SAFETY INFORMATION 1 1 Location of important labels 1 5 DESCRIPTION o ae 2 1 Left ViOW corpose ogoogo geniin 2 1 Right ViOW eessen 2 2 Controls and instruments 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 1 Main switch steering lock 4 3 1 Indicator and warning lights 3 2 Multi function meter unit 3 4 Handlebar switches seeen 3 8 Clutch lever eeeeeeeeeeseeeeeeeeneees 3 9 Shift pedal sanean 3 9 Brake lever csscceeseceeserereeeees 3 10 Brake pedal isinsin 3 10 Fuel tank cap eeen 3 10 BUC E E T 3 11 Catalytic converter cecee 3 12 SOatS EEEE E E E EE 3 12 Storage compartment 25 3 14 Adjusting the front fork osses 3 14 Adjusting the shock absorber assembly eeeceeseceeeeeseeeeeeees 3 16 Luggage strap holders 4 3 18 EXUP system saiat 3 18 Sidestand ooo eeeeeeeeeeeeeseeeees 3 18 Ignition circuit cut off system 3 19 PRE OPERATION CHECKS 4 1 Pre operation check list 4
73. oke 77 0 x 53 6 mm 3 03 x 2 11 in Compression ratio 11 50 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE10W30 or SAE20W40 we 30 50 70 90 11081905F wn i YAMALUBE 4 10W30 i _or SAE 10W30 j i ean en a _1 _ 1 gt YAMALUBE 4 20W40 or SAE 20W40 1 1 1 ies apt oma E el Ne l i i i i i i i i i i i i i hot i i 0 i i i i i i Peale e leat 20 10 0 10 20 30 40 50 C Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt With oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element 8 1 Fuel Recommended fuel 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 injector 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 reducti
74. om 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 EAU26400 Vehicle identification number 1 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key 9 1 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 number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area CONSUMER INFORMATION EAU26470 Model label 1 Model label The model label is affixed to the frame under the rider seat See page 3 12 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION EAU26551 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an
75. ometer needle 3 LCD 4 Brightness level This function allows you to adjust the brightness of the LCD and the tachom eter panel and needle to suit the out side lighting conditions To set the brightness 1 2 3 Turn the key to OFF Push and hold the SELECT but ton Turn the key to ON and then re lease the SELECT button after five seconds Push the RESET button to select the desired brightness level Push the SELECT button to con firm the selected brightness level The display will return to the odom eter or tripmeter mode INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Handlebar switches Left O 3 4 1 Dimmer switch 20 20 2 Turn signal switch lt 8 5 gt 3 Horn switch pes 4 Hazard switch A Right 1 Engine stop switch O R 2 Start switch 3 8 EAU12400 Dimmer switch 0 20 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 gt To signal a left hand turn push this switch to lt When re leased the switch returns to the center 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 s
76. on 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 27 20 1 350 6th 29 24 1 208 Chassis Frame type Diamond Caster angle 25 00 Trail 109 0 mm 4 29 in Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model MICHELIN Pilot Road S Manufacturer model DUNLOP D221FA Rear tire Type Tubeless Size 190 50 ZR17M C 73W Manufacturer model MICHELIN Pilot Road D Manufacturer model DUNLOP D221G Loading Maximum load 189 kg 417 Ib CAL 190 kg 419 Ib U49 Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 189 kg 198 417 Ib CAL 90 190 kg 198 419 Ib U49 Front 250 kPa 86 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 Front wheel Wheel type Cast wheel SPECIFICATIONS Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4
77. on system spare fuse e Always keep the battery charged Storing a discharged battery can cause permanent battery damage e To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery 6 31 PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses Main fuse 50 0 A Headlight fuse 20 0A Signaling system fuse 10 0 A Ignition fuse 15 0 A Fuel injection system fuse 15 0 A 1 Fuse box 1 Battery band Radiator fan fuse 2 Headlight fuse 2 Battery cover 10 0Ax2 3 Ignition fuse Backup fuse 4 Signaling system fuse 10 0 A 5 Backup fuse for odometer and clock 6 Right radiator fan fuse ECATOSID 7 Left radiator fan fuse 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 8 Spare fuse If a fuse is blown replace it as follows NOTE Include steps 2 and 6 only for the fuel fire MANOS OTS 1 Fuel injection system fuse 4 Turn the key to ON and turn on 1 Turn the key to OFF and turn off 2 Fuel injection system spare fuse the electrical circuit in question to the electrical circuit in question 3 Remove the blown fuse and then check if the device operates 2 Unhook the battery band and then install a new fuse of the specified 5 If the fuse immediately blows remove the battery cover amperage again
78. onditions 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 19 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 ECA15480 CAUTION The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light 5 1 e Coolant temperature warning light e Engine trouble warning light If a warning or indicator light does not go off see page 3 2 for the corre sponding warning and indicator light circuit check 2 Shift the transmission into the 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 serve the battery Do not crank the en gine more than 10 seconds on any one attempt OPERATION AND IMPORTANT RIDING POINTS ECA15490 CAUTION If the oil level warning light flick ers or rem
79. passenger footrests e Never ride under the influence of alcohol or other drugs 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 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 1 2 cause burns Always wear protec tive clothing that covers your legs ankles and feet e 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 s
80. ped 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 MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down 7 2 ECA10790 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motor
81. push the wheel forward 6 Remove the drive chain from the rear sprocket 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 The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel 6 38 Rese ae 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 EAU39411 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 Make sure that the slot in the brake caliper bracket is fit over the retain er on the swingarm Make sure that there is enough space between the brake pads be fore installing the wheel 1 Slot 2 Retainer 2 Install the drive chain onto the rear sprocket 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Adjust the drive chain slack See page 6 24 5 Tighten the axle nut to the speci fied torque Tightening torque Axle nut 150 Nm 15 0 m kgf 110 ft lbf PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from
82. s 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 e Hydraulic brake service e After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required e Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid e Replace the brake hoses every four years and if cracked or damaged 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing pan els 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 EAU40030 Panels A and B To remove one of the panels Remove the bolts and the screws and then pull the panel off as shown 1 Panel A 2 Screw 3 Bolt 6 8 To install the panel Place the panel in the original position and then install the screws and the bolts EAU19272 Panel C To remove the panel Remove the screw and then pull out ward on the areas shown 1 Panel C 2 Screw To install the panel Place the panel in the original position
83. se of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for EWA10621 any consequences caused by the use of items which have not been approved by Yamaha PERIODIC MAINTENANCE AND MINOR REPAIR EAU22080 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 in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 6 21 NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism PERIODIC MAINTENANCE AND MINOR REPAIR EAU22270 Adjusting the rear brake light switch 1 Rear brake light switch 2 Rear brake light switch adjusting nut The rear brake light switch which is 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 holdi
84. sh 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 EAU13220 Fuel 2 eee 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 3 11 ECA10070 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13300 Recommended fuel 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 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
85. sion control system PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi No ITEM ROUTINE 1000 km 7000 km 13000 km 19000 km 25000 km 31000 km or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months e Check fuel hoses for cracks or 1 Fuel line damage V V V V V e Replace if necessary e Check condition e Adjust gap and clean 2 Spark plugs Replace every 8000 mi 13000 Vy Replace V Replace Vy km or 12 months A e Check and adjust valve clearance i 3 Valve clearance when engine is cold Every 26600 mi 42000 km e Check breather hose for cracks or 4 peices breather damage N x N J N y e Replace if necessary 7 PBE e Check and adjust engine idle gt Fuelinjection speed and synchronization y A V V V y e Check for leakage 6 Exhaust system e Tighten if necessary V V V V V e Replace gasket s if necessary Evaporative emis e Check control system for dam 7 sion control system age V For California only e Replace if necessary ao f e Check the air cut off valve reed 8 ne Sys valve and hose for damage V y e Replace any damaged parts Since these items require special tools data and technical skills have a Yamaha dealer perform the service 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR General maintenance and lubrication c
86. 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 muffler outlet with a plastic bag to prevent moisture from entering it 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 30 NOTE Make any necessary repairs before storing the motorcycle the engine over 7 4 SPECIFICATIONS Dimensions Overall length 2140 mm 84 3 in Overall width 770 mm 30 3 in Overall height 1205 mm 47 4 in Seat height 815 mm 32 1 in Wheelbase 1460 mm 57 5 in Ground clearance 135 mm 5 31 in Minimum turning radius 3000 mm 118 1 in Weight With oil and fuel 220 0 kg 485 Ib U49 221 0 kg 487 Ib CAL Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined parallel 4 cylinder Displacement 998 0 cm Bore x str
87. t the wheel up between the fork legs 2 Insert the wheel axle 3 Install the brake caliper together with the reflector on each side by installing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Install the brake hose holder on each side by installing the bolt and nut 5 Take the vehicle off the center stand so that the front wheel is on the ground 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 6 37 Tightening torques Wheel axle 72 Nm 7 2 m kgf 52 ft lbf Front wheel axle pinch bolt 23 Nm 2 3 m kgf 17 ft lbf Brake caliper bolt 40 Nm 4 0 m kgf 29 ft Ibf 7 Push down hard on the handlebar several times to check for proper fork operation PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 Rear wheel EAU40020 To remove the rear wheel Itis 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 EWA10820 1 Loosen the axle nut Axle nut 1 2 Locknut 3 Drive chain slack adjusting bolt 4 Brake caliper 5 Brake caliper bracket 2 Place the vehicle on the center stand 3 Remove the axle nut 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a and
88. tabili 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 follow if loading cargo or adding acces sories to your motorcycle Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Maximum load 189 kg 417 Ib CAL 190 kg 419 Ib U49 When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize 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 A SAFETY INFORMATION 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 t
89. take 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 for one second and then the air in take temperature is displayed Self diagnosis device Hi F my camel TRIPA RESET SELECT 1 Error code display 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 display will indicate a two digit error code If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle 3 7 ECA11590 CAUTION If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage LCD and tachometer brightness control mode 1 Tachometer panel 2 Tach
90. te light bulb 1 Remove the license plate light unit by removing the screws 1 License plate light unit 2 Screw 2 Remove the socket together with the bulb by pulling it out 1 License plate light bulb 3 4 5 Install the license plate light unit by EAU24360 Remove the defective bulb by pull ing it out Insert a new bulb into the socket Install the socket together with the bulb by pushing it in Front wheel EAU40200 To remove the front wheel Itis advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over EWA10820 installing the screws 1 Place the vehicle on the center stand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 1 Front wheel axle pinch bolt 2 Wheel axle 6 36 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper togeth er with the reflector on each side by removing the bolts Brake hose holder Bolt and nut Brake caliper bolt Brake caliper Reflector akwnr ECA11050 CAUTION Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut 5 Pull the wheel axle out and then remove the wheel PERIODIC MAINTENANCE AND MINOR REPAIR EAU40210 To install the front wheel 1 Lif
91. ted parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Lid DUNLOP D221FA Rear tire Size 190 50 ZR17M C 73W Manufacturer model MICHELIN Pilot Road D DUNLOP D221G FRONT and REAR Tire air valve TR412 Valve core 9100 original This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires e Use only the specified replace meni 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 e Always make sure that the valve caps are securely installed to prevent air pressure leakage 2 3 A e Use only the tire valves and Tire information EWA10600 1 valve cores listed below to avoid tire deflation during a high speed ride fi A 1 Tire air valve 2 Tire air valve core 3 Tire air valve cap with seal 6 19 PERIODIC MAINTENANCE AND MINOR REPAIR broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a
92. 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 6 39 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 m gt There is enough fuel gt Check the compression Check the fuel level in the fuel tank Th ned Ten e engine does not start Th fuel m ASIS ee Supply fuel Check the compression 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 g Wet Pa Wipe off with a dry cloth and correct the Operate the electric starter sp
93. 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 change your clothes A SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle A SAFETY INFORMATION CAUTION e Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield e Use neutral detergent 5JW 01 2 California only EMISSION HOSE ROUTING FUEL TANK ATMOSPHERE 5SL 21686 00 A WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 1 6 AWARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 LOAD LIMIT 3 kg 7 Ibs 3TB 24877 A0 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90kg 198 Ibs load FRONT 250 kPa 2 50 kgf cm 36 psi REAR __ 290 kPa 2 90 kgf cm 42 psi 90 kg 198 Ibs maximum load FRONT 250 kPa 2 50 kgf cm 36 psi REAR 290 kPa 2 90 kgf cm
94. tion N Ni link pivots e Correct if necessary 20 Engine oil Change warm engine before X N J J J J draining a1 Engine oil filter car Replace N N J tridge e Check hoses for cracks or dam age V V V V V 22 Cooling system e Replace if necessary e Change with ethylene glycol anti freeze coolant every 24 months Change 23 Frontand rear brake Check operation V V V V V V switches e Apply Yamaha chain and cable 24 Control cables lube or engine oil SAE 10W 30 V V V V V V thoroughly e Check operation and free play _ Adjust the throttle cable free play 25 ech if necessary V V V V V g e Lubricate the throttle grip housing and cable 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Lights signals and switches Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE e Check operation e Adjust headlight beam Ni Ni Ni Ni Ni Ni From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months NOTE EAU17650 Air filter e Thi
95. 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 AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES EWA10010 IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without
96. top switch 2 3 Set this switch to CQ before starting the engine Set this switch to sq 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 INSTRUMENT AND CONTROL FUNCTIONS ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12764 Hazard switch A With the key in the ON position turn this switch to A to turn on the hazard 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 time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever EAU12870 Shift pedal 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
97. transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission 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 EAU16680 To start out and accelerate 1 2 Pull the clutch lever to disengage the clutch Shift the transmission into first gear The neutral indicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly OPERATION AND IMPORTANT RIDING POINTS 4 NOTE At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion Open the throttle part way and gradually release the clutch lever Follow the same procedure when shifting to the next higher gear Always shift gears at the recommended shift points EAU16700 To decelerate 1 2 Apply both the front and the rear brakes to slow the motorcycle Shift the transmission into first gear when the motorcycle reaches 25 km h 15 5 mish If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 5 3 3 Shift the transmission into the neu
98. your heavi EWA10510 est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Operation of an overloaded vehicle could cause tire damage an accident or even injury 6 18 Tire inspection 1 Tire sidewall 2 Tire wear indicator 3 Tire tread depth Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Minimum tire tread depth front and rear 1 0 mm 0 04 in PERIODIC MAINTENANCE AND MINOR REPAIR This motorcycle is equipped with cast Front tire wheels and tubeless tires with valves Size EWA10480 120 70 ZR17M C 58W 7 WARNING Manufacturer model e The front and rear tires should EWA10580 e It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines MICHELIN Pilot Road S have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake rela

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