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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

EAU01356

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
To increase the clutch lever free play,
turn the adjusting bolt at the clutch le-
ver in direction

a

. To decrease the

clutch lever free play, turn the adjusting
bolt in direction

b

.

NOTE:

@

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

@

1. Fully turn the adjusting bolt at the

clutch lever in direction

a

to loos-

en the clutch cable.

2. Remove cowling A. (See page 6-5

for cowling removal and installa-
tion procedures.)

3. Loosen the locknut at the crank-

case.

4. To increase the clutch lever free

play, turn the adjusting nut in di-
rection

a

. To decrease the clutch

lever free play, turn the adjusting
nut in direction

b

.

5. Tighten the locknut.
6. Install the cowling.

1. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Locknut
2. Clutch lever free play adjusting nut

E_5jj.book Page 23 Monday, September 11, 2000 6:56 PM

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Summary of Contents for 2001 YZF-R1N

Page 1: ...PRINTED IN JAPAN 2000 8 0 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5JJ 28199 21 YZF R1N OWNER S MANUAL ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ...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 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 4: ... be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5jj book Page 2 Monday September 11 2000 6 56 PM ...

Page 6: ...NUAL 2000 by Yamaha Motor Co Ltd 1st Edition August 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5jj book Page 3 Monday September 11 2000 6 56 PM ...

Page 7: ...ND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 8: ...E_5jj book Page 2 Monday September 11 2000 6 56 PM ...

Page 9: ...NFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 10: ...NICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle M...

Page 11: ...nering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator fo...

Page 12: ...ation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your moto...

Page 13: ...cessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution when selecting and installing any accessories Keep the following guidelines in mind as well as those provided under Loading when mounti...

Page 14: ...Y FLAMMABLE a Always turn the engine off when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame 2 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 y...

Page 15: ... may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes E_5jj book Page 6 Monday September 11 2000 6 56 PM ...

Page 16: ...AFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 E_5jj book Page 7 Monday September 11 2000 6 56 PM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 18: ...ork spring preload adjusting bolt page 3 14 4 Air filter element page 6 16 5 Shift pedal page 3 9 6 Shock absorber compression damping force adjusting screw page 3 17 7 Passenger seat lock page 3 12 8 Shock absorber rebound damping force adjusting screw page 3 17 9 Luggage strap holders page 3 20 10 Helmet holders page 3 13 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 19: ...4 Battery page 6 34 15 Shock absorber spring preload adjusting ring page 3 16 16 Radiator and coolant reservoir page 6 12 17 Front brake fluid reservoir page 6 26 18 Engine oil filter cartridge page 6 9 19 Engine oil level check window page 6 9 20 Brake pedal page 3 10 E_5jj book Page 2 Monday September 11 2000 6 56 PM ...

Page 20: ...dlebar switches page 3 8 3 Starter choke lever page 3 11 4 Speedometer unit page 3 5 5 Main switch steering lock page 3 1 6 Tachometer page 3 6 7 Right handlebar switches page 3 8 8 Throttle grip page 6 19 9 Brake lever page 3 9 E_5jj book Page 3 Monday September 11 2000 6 56 PM ...

Page 21: ...9 Brake lever 3 9 Brake pedal 3 10 Fuel tank cap 3 10 Fuel 3 11 Starter choke lever 3 11 Seats 3 12 Helmet holders 3 13 Storage compartment 3 14 Adjusting the front fork 3 14 Adjusting the shock absorber assembly 3 16 Matching the front and rear suspension settings 3 19 Luggage strap holders 3 20 EXUP system 3 20 Sidestand 3 21 Ignition circuit cut off system 3 21 E_5jj book Page 1 Monday Septembe...

Page 22: ...40 LOCK The steering is locked and all electrical systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK w...

Page 23: ...If the warning light does not come on have a Yamaha dealer check the electrical circuit NOTE This model is equipped with a self di agnosis device for the fuel level warn ing light circuit See page 3 7 for an explanation of the self diagnosis de vice EAU03285 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 check...

Page 24: ...gine to cool The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the key to ON 2 If the warning light does not come on have a Yamaha dealer check the electrical circuit EC000002 CAUTION Do not operate the engine if it is overheated 1 Coolant temperature gauge 2 Coolant temperature warning light E_5jj book Page 3 Monday September 11 2000 6 56 PM ...

Page 25: ...rning light comes on Stop the motorcycle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See the Engine overheating section on page 6 45 for further instructions Above 140 C Message HI flashes Warning light comes on Stop the engine and allow it to cool See the Engine overheating sec tion on page 6 45 for further in structions E_5jj b...

Page 26: ... change to the fuel re serve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the dis play between the various tripmeter and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F 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 n...

Page 27: ...igits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock EAU00101 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003 CAUTION Do not operate the engine in the ta chometer red zone Red zone 11 750 r min and above 1 Tachometer 2 Tachometer red zone...

Page 28: ...ter displays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage This model is also equipped with a self diagnosis device for the fuel level warn ing light circuit If the fuel level warning light circuit is defective the following cycle will be repeated until the malfunc tion is corrected The warning light will flash eight times then go off for three ...

Page 29: ...signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU00138 Engine stop switch Set this switch to to stop the en gine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See pa...

Page 30: ...ion with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 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 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 ...

Page 31: ... tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover 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 EWA00025 WARNING Make sur...

Page 32: ...pe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU00192 EAU02976 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke 1 Fuel tank filler tube 2 Fuel level...

Page 33: ...t of the rider seat into the seat holder as shown place the seat in the original position and then install the bolts Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward 1 Bolt 2 1 Projection 2 Seat holder 1 Passenger seat lock 2 Unlock E_5...

Page 34: ...t To secure a helmet to a helmet holder 1 Remove the passenger seat See page 3 12 for removal and instal lation procedures 2 Attach the helmet to a helmet holder and then securely install the passenger seat EWA00015 WARNING Never ride with a helmet attached to a helmet holder since the helmet may hit objects causing loss of control and possibly an accident To release the helmet from a helmet holde...

Page 35: ... with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting screws EW000035 WARNING Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload 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...

Page 36: ...turn the adjusting screw on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b CI 33E 1 Current setting 2 Front fork cap bolt Minimum soft Stan dard Maximum hard Setting 8 7 6 5 4 3 2 1 1 Rebound damping force adjusting screw Minimum soft 11 clicks in direction b Standard 5 clic...

Page 37: ...ck absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and rebound and compression damping force adjusting screws EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spri...

Page 38: ...s 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 1 Rebound damping force ad...

Page 39: ... property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock 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...

Page 40: ...onditions CI 31E EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload Compression damping force Rebound damping force Spring preload Compression damping force Rebound damping force Rider only 1 8 1 9 1 11 1 7 4 11 3 11 With passenger 1 8 1 9 1 11 4 9 1 9 1 7 E_5jj ...

Page 41: ...a s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servomotor EC000027 CAUTION The EXUP system has been set and extensively tested at the Yamaha factory Changing these settings without sufficient tech...

Page 42: ...lling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the t...

Page 43: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 44: ...E_5jj book Page 23 Monday September 11 2000 6 56 PM ...

Page 45: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 46: ...ge 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 25 6 27 Rear brake Check operation If...

Page 47: ...s Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 19 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 30 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 3...

Page 48: ...E_5jj book Page 3 Monday September 11 2000 6 56 PM ...

Page 49: ...NT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 50: ...tem to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sid estand up EW000054 WARNING Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 22 Never ride with the sidestand down 1 Turn the key to ON ...

Page 51: ...aler check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on when pushing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5...

Page 52: ...on press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transm...

Page 53: ... let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km For this rea son you should read the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km Th...

Page 54: ... any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle NOTE During and after the engine break in period the exhaust heat may cause discoloration of the exhaust pipe but this is normal EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can beco...

Page 55: ... pads 6 25 Checking the brake fluid level 6 26 Changing the brake fluid 6 27 Drive chain slack 6 27 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 30 Checking and lubricating the brake and clutch levers 6 30 Lubricating the brake pedal 6 31 Checking and lubricating the sidestand 6 31 Lubricating the rear suspension 6...

Page 56: ... maintenance work have a Yamaha dealer do it for you EAU01575 Owner s tool kit The tool kit is located inside the storage compartment under the passenger seat See page 3 12 for passenger seat removal procedures 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 ...

Page 57: ...ne Check fuel hoses and vacuum hose for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit...

Page 58: ...based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm and connecting arm pivoting points Check operatio...

Page 59: ...id Replace the brake hoses every four years and if cracked or damaged 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Air induction system Check the air cut valve and reed valve for damage Replace the entire air induction system if necessary 29 Muffler and exhaust pipe Check the screw clamp for looseness 30 Lights signals and switches Check operation Adjust...

Page 60: ... be re moved and installed EAU03536 Cowling A To remove the cowling Remove the screw loosen the quick fastener screws 1 4 turn counterclock wise and then take the cowling off To install the cowling Place the cowling in the original posi tion and then tighten the quick fastener screws and install the screw 1 Cowling A 2 Cowling B 3 Panel A 1 Quick fastener screw 4 2 Screw Right side 1 Quick fastene...

Page 61: ...remove the cowling 1 Remove cowling A and panel A 2 Disconnect the turn signal light lead connectors 3 Remove the screw loosen the quick fastener screws remove the quick fastener at the front of the cowling and then take the cowling off NOTE The quick fastener is removed by push ing the center pin in with a screwdriver then pulling the fastener out 1 Screw 2 Quick fastener screw Right side 1 Lead ...

Page 62: ... 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 col or when the motorcycle is ridden nor mally and all spark plugs inst...

Page 63: ...ting surface and then wipe off any grime from the spark plug threads 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 a Spark plug gap Spark plug gap 0 7 0 8 mm Tightening torque Spark plug 12 5 Nm 1 25 m kg E_5jj book ...

Page 64: ...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 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended ty...

Page 65: ...drain the oil from the crankcase NOTE Skip steps 6 8 if the oil filter cartridge is not being replaced 6 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 1 Engine oil drain bolt 1 Oil filter wrench 2 Oil...

Page 66: ... not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient 1 Torque...

Page 67: ...t position NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the coolant reservoir NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is ...

Page 68: ...E The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor When the engine is idling with the starter choke turned on the radi ator fan will automatically be switched on and off regardless of the coolant temperature but this does not indicate a malfunction If the engine overheats see page 6 44 for further instructions EAU01577 To change the coolant...

Page 69: ...he coolant drain bolt to drain the cooling system 8 Loosen the radiator hose clamp screw located at the left side of the engine and then pull off the hose to drain the radiator 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place...

Page 70: ...e reduced 13 Install the radiator cap start the engine let it idle for several min utes and then turn it off 14 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 15 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the...

Page 71: ...n procedures 2 Remove the bolt at the front of the fuel tank and loosen the bolt at the rear 3 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 EW000071 WARNING Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 4 Remo...

Page 72: ...hout the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by installing the screws and bolt 9 Place the fuel tank in the original position and then install the bolt at the front and tighten the bolt at the rear EW000072 WARNING Before installing the fuel tank make sure that the fuel hoses are not damaged If any f...

Page 73: ...Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally revving it to 4 000 5 000 r min NOTE The engine is warm when it quickly re sponds to the throttle 2 Check the engine i...

Page 74: ...ecified in the periodic maintenance and lubrication chart EAU03296 Tires To maximize the performance durability and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 WARNING The tire air pressure must be checked and adjusted on cold tires i e when th...

Page 75: ...ed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury Tire inspection 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 T...

Page 76: ...gulations Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves EW000080 WARNING The front and rear tires should be of the same make and design otherwise the handling charac teristics of the motorcycle can not be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the val...

Page 77: ...e operation of your motor cycle 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...

Page 78: ... free play cannot be obtained as described above proceed as follows 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Remove cowling A See page 6 5 for cowling removal and installa tion procedures 3 Loosen the locknut at the crank case 4 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free pla...

Page 79: ...lic system will diminish the braking performance which may result in loss of control and an accident EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear b...

Page 80: ...cator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU01248 Rear brake pads 1 Remove the rear brake caliper by removing the bolts 1 Brake pad wear ...

Page 81: ... necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate ...

Page 82: ...ange the brake fluid at the intervals specified in the periodic maintenance and lubrica tion chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU00744 Drive chain slack The drive chain slack shoul...

Page 83: ...n 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 EC000096 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 th...

Page 84: ...2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and ...

Page 85: ... then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by installing the screws EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers sh...

Page 86: ...s should be lubricated if necessary EW000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU03166 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recomme...

Page 87: ...s no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork ...

Page 88: ...support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU01144 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...

Page 89: ... 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 minutes and seek prompt medical attention 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 KEEP THIS...

Page 90: ...box which contains the fuses for the individual cir cuits are located under the rider seat See page 3 12 for rider seat removal and installation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Headlight fuse 2 Radiator fan fuse 3 Ignition fuse 4 ...

Page 91: ...es 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU03295 Replacing a headlight bulb This motorcycle is equipped with two quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the headlight bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 1 Headllight cou...

Page 92: ...ulb to keep it free from oil otherwise the transpar ency of the glass the luminosi ty 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 head light lens Do not use a headlight bulb of a wattage higher th...

Page 93: ... socket together with the bulb by turning it counter clockwise 4 Remove the defective bulb by pushing it in and turning it counter clockwise 5 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the bulb cover 8 Install the passenger seat 1 Tail brake light bulb cover 1 Socket E_5jj bo...

Page 94: ...r maintenance requiring the motorcycle to stand upright Check that the motorcycle is in a stable and level position before start ing any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the fra...

Page 95: ...en the wheel axle and the brake caliper bolts 3 Lift the front wheel off the ground according to the procedure on page 6 39 4 Remove the brake hose holders on each side by removing the bolts 5 Remove the brake caliper on each side by removing the bolts 6 Pull the wheel axle out and then remove the wheel ECA00046 CAUTION Do not apply the brake after the brake calipers have been removed otherwise th...

Page 96: ... bolt and brake caliper bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation 8 Install the cowling EAU03537 Rear wheel To remove the rear wheel EW000122 WARNING It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut and the brake calip...

Page 97: ...he wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 7 Pull the wheel axle out and then remove the wheel ECA00048 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 1 Brake caliper bolt 2 E_5jj ...

Page 98: ...ng Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any r...

Page 99: ...mpression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Operate the electric starter 4 Battery The engine turns over quickly The engine turn...

Page 100: ...hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap 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 Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check t...

Page 101: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 102: ...ghtly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00056 CAUTION _ Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to re...

Page 103: ... shield is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After ridi...

Page 104: ... is normal and cannot be removed After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts 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 5 Us...

Page 105: ...ater 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 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to ...

Page 106: ... turning the engine over _ 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cove...

Page 107: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 108: ...lectric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 7 L With oil filter cartridge replacement 2 9 L Total amount dry engine 3 6 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti fr...

Page 109: ...y reduction ratio 1 581 Secondary reduction system Chain drive Secondary reduction ratio 2 688 Number of drive chain sprocket teeth front rear 16 43 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 500 2nd 1 842 3rd 1 500 4th 1 333 5th 1 200 6th 1 115 Chassis Frame type Diamond Caster angle 24 Trail 92 mm Tires Front Type Tubeless tire Size 120 70 ZR17 58 W Manufacturer...

Page 110: ...l Size 17 MT 3 50 Rear Type Cast wheel Size 17 MT 6 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 135 mm Rear 130 mm Electrical system Ignition system...

Page 111: ...r lighting LED 2 Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Oil level warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Radiator fan fuse 10 A Ignition fuse 15 A Odometer fuse 10 A E_5jj book Page 4 Monday September 11 2000 6 56 PM ...

Page 112: ...etric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 113: ...ORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation for Australia 9 2 E_5jj book Page 1 Monday September 11 2000 6 56 PM ...

Page 114: ...01E EAU01041 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 EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify y...

Page 115: ...RING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of...

Page 116: ...Engine idling speed 6 18 Engine oil and oil filter cartridge 6 9 Engine stop switch 3 8 EXUP system 3 20 F Front and rear suspension settings 3 19 Front fork adjusting 3 14 Front fork checking 6 32 Fuel 3 11 Fuel consumption tips for reducing 5 4 Fuel level warning light 3 2 Fuel tank cap 3 10 Fuses replacing 6 35 H Handlebar switches 3 8 Headlight bulb replacing 6 36 Helmet holders 3 13 High beam...

Page 117: ...compartment 3 14 Supporting the motorcycle 6 39 Suspension rear lubricating 6 31 T Tachometer 3 6 Tail brake light bulb replacing 6 38 Throttle cable free play adjusting 6 19 Throttle grip and cable checking and lubricating 6 30 Tires 6 19 Tool kit 6 1 Troubleshooting 6 43 Troubleshooting charts 6 44 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 39 Turn signal switch 3 8 V Val...

Page 118: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 119: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 120: ...PRINTED IN JAPAN 2000 8 0 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5JJ 28199 21 YZF R1N OWNER S MANUAL ...

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