Yamaha 2001 YZF-R6M Page 90 Owner'S Manual Download

Page: 90 / 117

PERIODIC MAINTENANCE AND MINOR REPAIR

6-35

EAU01822

Headlight bulb replacement

This motorcycle is equipped with a
quartz bulb headlight.
If the headlight bulb burns out, replace
the bulb as follows:

1. Remove panel C. (See page 6-8

for panel removal and installation
procedures.)

2. Remove the headlight connector

and the bulb holder cover.

3. Unhook the bulb holder and re-

move the defective bulb.

Specified fuses:

Main fuse:

30 A

Headlight fuse:

20 A

Signaling system fuse:

20 A

Radiator fan fuse:

7.5 A

Ignition fuse:

15 A

Odometer fuse:

7.5 A

1. Connector
2. Bulb holder cover

1. Bulb holder

E_5eb_Periodic.fm Page 35 Monday, February 7, 2000 9:04 AM

Summary of Contents for 2001 YZF-R6M

Page 1: ...5EB 28199 22 YZF R6M OWNER S MANUAL ...

Page 2: ...P_5jj_Periodic fm Page 45 Friday February 4 2000 10 27 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 about the operation or maintenance of your motorcycle please consult a Yamaha dealer E_5eb_Intro0 fm Page 1 Monday February 7 2000 8 57 AM ...

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 informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5eb_Info0 fm Page 2 Monday February 7 2000 8 57 AM ...

Page 6: ...UAL 2000 by Yamaha Motor Co Ltd 1st Edition January 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_5eb_Info0 fm Page 3 Monday February 7 2000 8 57 AM ...

Page 7: ...D 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_5eb_Toc0 fm Page 1 Monday February 7 2000 8 58 AM ...

Page 8: ...E_5eb_Toc0 fm Page 2 Monday February 7 2000 8 58 AM ...

Page 9: ...RMATION Safe riding 1 1 Protective apparel 1 3 Modification 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of the important labels 1 7 E_5eb_SafetyTOC fm Page 1 Monday February 7 2000 8 58 AM ...

Page 10: ...Y MECHANICAL 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 motor...

Page 11: ...icient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure other motorists see you 6 The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the operator footrests during operat...

Page 12: ...ecome 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 Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illega...

Page 13: ...g such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You should use extr...

Page 14: ...ility Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to...

Page 15: ... heater or near an open flame The motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright If it should lean over gasoline 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 in your eyes see your doctor immediately If any gasoline spills on your skin or clothing...

Page 16: ...e important labels Please read the following labels carefully before operating this motorcycle WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 2 E_5eb_Safety fm Page 7 Monday February 7 2000 8 58 AM ...

Page 17: ...2 DESCRIPTION Left view 2 1 Right view 2 2 Controls Instruments 2 3 E_5eb_DescriptionTOC fm Page 1 Monday February 7 2000 8 59 AM ...

Page 18: ...usting bolt page 3 17 4 Air filter page 6 17 5 Rear shock absorber compression damping force adjusting screw page 3 20 6 Rear shock absorber spring preload adjusting ring page 3 19 7 Rear shock absorber rebound damping force adjusting knob page 3 19 8 Shift pedal page 3 11 9 Coolant reservoir tank page 6 13 10 Engine oil filter page 6 11 E_5eb_Description fm Page 1 Monday February 7 2000 9 00 AM ...

Page 19: ... strap holders page 3 22 12 Tool kit page 6 1 13 Fuses page 6 34 14 Rear brake fluid reservoir 15 Radiator cap page 6 14 16 Front brake fluid reservoir 17 Rear brake pedal page 3 12 E_5eb_Description fm Page 2 Monday February 7 2000 9 00 AM ...

Page 20: ...ar switches page 3 9 20 Starter choke page 3 14 21 Digital speedometer page 3 7 22 Main switch page 3 1 23 Tachometer page 3 8 24 Right handlebar switches page 3 10 25 Throttle grip page 6 21 26 Front brake lever page 3 11 E_5eb_Description fm Page 3 Monday February 7 2000 9 00 AM ...

Page 21: ...utch lever 3 11 Shift pedal 3 11 Front brake lever 3 11 Rear brake pedal 3 12 Fuel tank cap 3 13 Fuel 3 13 Starter choke 3 14 Seats 3 15 Helmet holder 3 16 Storage compartment 3 16 Front fork adjustment 3 17 Rear shock absorber adjustment 3 19 Recommended combinations of the front fork and the rear shock absorber settings 3 21 Luggage strap holders 3 22 Sidestand 3 22 Sidestand clutch switch opera...

Page 22: ...OCK The steering is locked in this position and all electrical circuits are switched off The key can be removed in this po sition To lock the steering turn the handle bars all the way to the left While push ing the key into the main switch turn it from OFF to LOCK and remove it To release the lock turn the key to OFF while pushing EW000016 WARNING Never turn the key to OFF or LOCK when the motorcy...

Page 23: ...tor light This indicator flashes when the turn switch is moved to the left or right EAU01154 Fuel indicator light When the fuel level drops below ap proximately 3 5 L this light will come on When this light comes on fill the tank at the first opportunity This light circuit can be checked by the proce dure on page 3 6 1 Neutral indicator light 2 High beam indicator light 3 Turn indicator light 4 Fu...

Page 24: ...ions of the indicator light symbol and temper ature display in accordance to coolant temperature The light circuit can be checked by the procedure on page 3 5 EC000118 CAUTION Do not run the motorcycle until you know it has sufficient en gine oil Do not run the motorcycle if the engine is overheated NOTE Even if the oil is filled to the specified level the indicator light may flicker when riding o...

Page 25: ... Indicator light comes on Stop the motorcycle and allow it to idle until coolant temperature goes down If the temperature does not go down stop the engine See En gine overheating in the trouble shooting chart on page 6 42 for instructions 141 C Symbol and message HI flash Indicator light comes on Stop the engine and allow it to cool See Engine overheating in the troubleshooting chart on page 6 42 ...

Page 26: ...temperature See page 3 4 Indicator goes off No symbol is on Symbol or is on OK Go ahead with riding Indicator does not go off If symbol is on inspect the oil level Oil level is OK Oil level is low Have a Yamaha dealer inspect the electrical circuit Supply recommended engine oil If the engine is hot allow it to cool and see Engine overheating in the troubleshooting chart on page 6 42 for instructio...

Page 27: ...Have a Yamaha dealer inspect the electric circuit Indicator goes off Indicator does not go off Inspect the fuel level Indicator comes on After a few seconds OK Go ahead with riding Fuel level is OK Have a Yamaha dealer inspect the electric circuit Fuel level is low Supplyrecommended fuel E_5eb_Functions fm Page 6 Monday February 7 2000 9 01 AM ...

Page 28: ...start counting the distance traveled from that point Push the SELECT button to change between the fuel odometer trip odometer and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F Resetting a meter To reset a trip odometer to 0 0 select it by pushing the SELECT button and push the RESET button for at least one second To reset the fuel reserve trip meter select it by pushing the...

Page 29: ...ge the minutes 4 When the minute digits start flash ing push the RESET button to set the minutes 5 Push the SELECT button to start the clock NOTE After setting the clock be sure to push the SELECT button before turning the main switch to OFF otherwise the clock will not be set EAU00101 Tachometer This model is equipped with an electric tachometer so the rider can monitor the engine speed and keep ...

Page 30: ...to a Yamaha dealer for repair EC000004 CAUTION To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if the tachometer dis plays a repeated change in r min EAU00118 Handlebar switches EAU00120 Pass switch PASS Press the switch to operate the passing light EAU00121 Dimmer switch Turn the switch to for the high beam and to for the low beam Specified r min for the faulty cir...

Page 31: ...h to sound the horn EAU00138 Engine stop switch The engine stop switch is a safety de vice for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to to start the en gine In case of emergency turn the switch to to stop the engine EAU00143 Start switch The starter motor cranks the engine when pushing the start switch EC000005 CAUTION...

Page 32: ...ation Refer to the engine starting pro cedures for a description of the ignition circuit cut off system EAU00157 Shift pedal This motorcycle is equipped with a con stant mesh 6 speed transmission The shift pedal is located on the left side of the engine and is used in com bination with the clutch when shifting EAU00161 Front brake lever The front brake lever is located on the right handlebar and i...

Page 33: ...re the setting on the brake lever adjusting dial is aligned with the arrow mark EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake 1 Lever position adjusting dial 2 Arrow mark a Lever distance 1 Rear brake pedal E_5eb_Functions fm Page 12 Monday February 7 2000 9 01 AM ...

Page 34: ... key cannot be removed if the cap is not locked properly EW000023 WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle EAU01183 Fuel Make sure there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion EW000130 WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill...

Page 35: ...ure Move in direction a to turn on the start er choke Move in direction b to turn off the start er choke ECA00038 CAUTION Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat Also longer use of the starter choke will cause afterburning If af terburning occurs turn off the start er choke Recommended fuel Regular gasoline For Australia Unleaded fu...

Page 36: ...tion on the front of the seat into the seat holder and install the bolts Passenger seat To remove Insert the key into the seat lock and turn it counterclockwise While holding the key in that position lift up the front of the seat and pull it forward 1 Bolt 2 1 Projection 2 Seat holder 1 Passenger seat lock 2 Open E_5eb_Functions fm Page 15 Monday February 7 2000 9 01 AM ...

Page 37: ...hen install the passenger seat EW000030 WARNING Never ride with a helmet in the hel met holder The helmet may hit ob jects causing loss of control and possibly an accident EAU01242 Storage compartment The storage compartment is located under the passenger seat Refer to page 3 15 for details on how to open the seat EW000033 WARNING Do not exceed maximum load Maxi mum load 3 kg 1 Projection 2 Seat h...

Page 38: ...n the adjusting bolt in direction a to increase spring preload and in direction b to decrease spring pre load Align the preferred setting with the top of the front fork cap EC000013 CAUTION The grooves are provided to show the adjustment level Always keep the adjustment level equal on both fork legs 1 Spring preload adjusting bolt 1 Setting position 2 Front fork cap bolt COPY CI 18ECI 18E Hard Sof...

Page 39: ...e maximum or minimum setting NOTE Although the number of clicks between the minimum and maximum settings may vary with each individual shock absorber and may not exactly match these specifications it is always the full damping force range that extends over the actual number of clicks 1 Rebound damping force adjusting screw Minimum soft 9 clicks out Standard 6 clicks out Maximum hard 1 click out Fr...

Page 40: ...ppropriate notch in the adjusting ring is aligned with the po sition indicator on the rear shock ab sorber CI 18E Adjusting rebound damping force Turn the adjusting knob in direction a to increase rebound damping force and in direction b to decrease rebound damping force CI 34E 1 Spring preload adjusting ring 2 Special wrench 3 Position indicator Hard Stan dard Soft Adjusting position 9 8 7 6 5 4 ...

Page 41: ...rstand the following infor mation before handling the shock absorber The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not...

Page 42: ...E EC000016 CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting Loading condition Front fork adjustment Rear shock absorber adjustment Spring preload Compression damping force Rebound damping force Spring preload Compression damping force Rebound damping force Solo rider 1 8 1 10 1 9 1 7 4 13 3 25 With passenger 1 8 1 10 1 9 4 9 1 8 1 7 E_5eb_Functions fm Page 21 Monday...

Page 43: ...his motorcycle must not be operat ed with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the operator re sulting in a possible loss of control Yamaha has designed into this motorcycle a lockout system to as sist the operator in fulfilling the re sponsibility of retracting the sidestand Please check carefully the operating instruct...

Page 44: ... 11E EW000045 WARNING If improper operation is noted con sult a Yamaha dealer immediately TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START SIDESTAND IS DOWN CLUTCH SWITCH IS OK ENGINE WILL STALL SIDESTAND SWITCH IS OK E_5eb_Functions fm Page 23 Monday February 7 2000 9 01 AM ...

Page 45: ...4 PRE OPERATION CHECKS Pre operation check list 4 1 E_5eb_PreopTOC fm Page 1 Monday February 7 2000 9 02 AM ...

Page 46: ... DOT 4 brake fluid if necessary 6 26 6 28 Rear brake 6 26 6 28 Clutch Check operation condition and free play Adjust if necessary 6 25 Throttle grip and housing Check for smooth operation Lubricate if necessary 6 21 6 30 Engine oil Check oil level Fill with oil if necessary 6 10 6 13 Coolant reservoir tank Check coolant level Fill with coolant if necessary 6 13 6 16 Drive chain Check chain slack a...

Page 47: ...E OPERATION CHECK is not working properly have it inspected and repaired before operating the motorcycle Sidestand pivot Check for smooth operation Lubricate if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Fuel Check fuel level Fill with fuel if necessary 3 13 3 14 Lights signals and switches Check for proper operation 6 35 6...

Page 48: ...E_5eb_Preop fm Page 3 Monday February 7 2000 9 02 AM ...

Page 49: ... RIDING POINTS Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 5 Parking 5 5 E_5eb_OperationTOC fm Page 1 Monday February 7 2000 9 03 AM ...

Page 50: ... Before starting out always be sure the sidestand is up Failure to retract the sidestand com pletely can result in a serious accident when you try to turn a corner EAU01383 Starting and warming up a cold engine NOTE This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under one of the following conditions The transmission is in neutral The sidestand i...

Page 51: ...L AND SIDESTAND IS DOWN PUSH THE START SWITCH ENGINE WILL START RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN THE CLUTCH LEVER AND PUSH START THE SWITCH ENGINE WILL START MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN E_5eb_Operation fm Page 2 Monday February 7 2000 9 03 AM ...

Page 52: ... pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds then try again Each attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one attempt 5 After starting the engine move the starter choke to the warming up position NOTE For maximum engine life always warm up the engine before starting...

Page 53: ...s use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch EAU00424 Tips for reducing fuel consumption Your motorcycle s fuel consumption depends to a large extent on your riding style The following tips can help reduce fuel consumption Warm up the engine before riding...

Page 54: ...AU01329 0 1 000 km Avoid operation above 5 000 r min 1 000 1 600 km Avoid cruising speeds in excess of 6 000 r min EC000052 CAUTION After 1 000 km of operation be sure to replace the engine oil and oil fil ter 1 600 km and beyond Proceed with normal riding EC000053 CAUTION Never let engine speeds enter the red zone If any engine trouble should oc cur during the break in period consult a Yamaha dea...

Page 55: ...level 6 27 Brake fluid replacement 6 28 Drive chain slack check 6 28 Drive chain slack adjustment 6 29 Drive chain lubrication 6 29 Cable inspection and lubrication 6 30 Throttle cable and grip lubrication 6 30 Brake and clutch lever lubrication 6 30 Brake pedal lubrication 6 31 Sidestand lubrication 6 31 Rear suspension lubrication 6 31 Front fork inspection 6 32 Steering inspection 6 32 Wheel be...

Page 56: ... lowing pages EW000060 WARNING If you are not familiar with motor cycle service this work should be done by a Yamaha dealer EAU01296 CAUTION Do not test this motorcycle on a dy namometer for an extended period of time as discoloration to the fiber constructed muffler may occur from the heat EAU01575 Tool kit The tool kit is located inside the storage compartment under the passenger seat See page 3...

Page 57: ...ice operation take your motorcycle to a Yamaha dealer for service EW000063 WARNING Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer before attempting any chang es E_5eb_Periodic fm Page 2 Monday February 7 2000 9 04 AM ...

Page 58: ...Adjust if necessary Every 42 000 km or 42 months whichever comes first 5 Air filter Replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 5 Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 5 Correct a...

Page 59: ...er comes first 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary 16 Sidestand Check operation Lubricate and repair if necessary 17 Sidestand switch Check operation Replace if necessary 18 Front fork Check operation and for oil leakage Correct accordingly 19 Rear shock absorber assembly Check operation and shock absorber for oil leakage Replac...

Page 60: ...n the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 22 Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining 23 Engine oil filter cartridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Correct if necessary Change coola...

Page 61: ... be removed to perform some of the maintenance described in this chapter Refer to this section each time a cowling or panel has to be removed or reinstalled EAU01602 Cowlings A and B To remove 1 Remove the screws 1 Cowling A right side Cowling B left side 2 Panel C 1 Screw 5 1 Screw 6 E_5eb_Periodic fm Page 6 Monday February 7 2000 9 04 AM ...

Page 62: ...at the rear bottom of the cowlings togeth er and slide the cowling into place 2 Place the cowling in its original po sition Make sure that the tabs at the front of the cowlings fit side by side as shown and that all slots and projections fit together 3 Install the screws 1 Cowling A 2 Cowling B 1 Slot 2 2 Projection 2 1 Tab 2 E_5eb_Periodic fm Page 7 Monday February 7 2000 9 04 AM ...

Page 63: ... MINOR REPAIR 6 8 6 EAU01315 Panel C To remove Remove the screws To install Place the panel in the original position and install the screws 1 Screw 2 1 Projection 2 Slot E_5eb_Periodic fm Page 8 Monday February 7 2000 9 04 AM ...

Page 64: ...pected because heat and de posits will cause any spark plug to slowly break down and erode If elec trode erosion becomes excessive or if carbon and other deposits are exces sive the spark plug should be replaced with the specified plug Before installing any spark plug mea sure the electrode gap with a wire thickness gauge and adjust it to specifi cation When installing a spark plug the gas ket sur...

Page 65: ...Engine oil Oil level inspection 1 Place the motorcycle on a level place and hold it in an upright posi tion Warm up the engine for seve ral minutes NOTE Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 2 Stop the engine and remove the dipstick NOTE Wait a few minutes until the oil level settles before checking 3...

Page 66: ...he engine and remove the dipstick 4 Remove the drain plug and drain the oil 5 Remove the oil filter by using an oil filter wrench NOTE An oil filter wrench is available at a nearby Yamaha dealer 6 Reinstall the drain plug and tighten it to the specified torque 1 Engine oil filler cap 1 Engine oil drain plug 1 Oil filter wrench 2 Oil filter cartridge Tightening torque Drain plug 43 Nm 4 3 m kg E_5e...

Page 67: ... reach the specified level Install the dipstick and tighten it EC000066 CAUTION Do not put in any chemical addi tives Engine oil also lubricates the clutch and additives could cause clutch slippage Be sure no foreign material en ters the crankcase 1 O ring 1 Torque wrench Tightening torque Oil filter 17 Nm 1 7 m kg Recommended oil See page 8 1 Oil quantity Total amount 3 5 L Periodic oil change 2 ...

Page 68: ... en gine and consult with a Yamaha dealer 12 Install the cowling EAU01611 Cooling system 1 Check the coolant level in the res ervoir tank when the engine is cold as the coolant level will vary with engine temperature The coolant level should be between the maxi mum and minimum marks 2 If the level is low remove the res ervoir tank cover by removing the bolts 3 Add coolant or distilled water to rai...

Page 69: ...e radiator 5 If your motorcycle overheats see page 6 42 for details EAU01612 Changing the coolant 1 Remove panel C cowling A and cowling B See page 6 6 for re moval and installation proce dures 2 Place a container under the en gine 3 Remove the radiator cap 4 Remove the water pump drain bolt and drain the coolant from the wa ter pump housing 5 Disconnect the radiator hose by loosening the clamp an...

Page 70: ... 10 Remove the reservoir tank by re moving the bolts 11 Remove the reservoir tank cap and turn the tank upside down to empty it 12 Install the reservoir tank 13 Fill the reservoir tank with coolant up to the maximum level then in stall the cap and cover 14 Pour the recommended coolant into the radiator until it is full Tightening torque Drain bolt 12 Nm 1 2 m kg 1 Bolt 2 1 Bolt 2 E_5eb_Periodic fm...

Page 71: ... diator If it is low fill with more coolant until it reaches the top of the radiator 17 Check for coolant leakage NOTE If you find any leaks ask a Yamaha dealer to inspect 18 Install the panel and the cowling Recommended anti freeze High quality ethylene glycol anti freeze containing corrosion inhib itors for aluminum engines Antifreeze and water mix ratio 1 1 Total amount 2 15 L Reservoir tank ca...

Page 72: ...lation procedures 2 Remove the bolts holding the fuel tank 3 Lift the fuel tank upward 4 Set the fuel cock to OFF 5 Disconnect the fuel sender lead coupler 6 Disconnect the hoses NOTE Before removing the hoses mark them to ensure that they will be reinstalled in their correct positions 7 Tilt the front of the fuel tank back away from the air filter case Be sure to support it as shown 1 Bolt 2 1 Fu...

Page 73: ...ews holding the air filter case cover 9 Remove the air filter element 10 Check the air filter element s con dition If it is damaged or exces sively dusty it should be replaced 1 Screw 6 1 Air filter element E_5eb_Periodic fm Page 18 Monday February 7 2000 9 04 AM ...

Page 74: ...d or cylin der wear may result 11 Reverse the removal procedure for installation EW000131 WARNING Make sure that the fuel hoses and vacuum hose are properly connect ed in place and not pinched If a hose is damaged be sure to replace it EAU01335 Air intake duct Check that the screen of the intake duct is not blocked Clean the screen if necessary 1 Air intake duct E_5eb_Periodic fm Page 19 Monday Fe...

Page 75: ...er formance and damage may result EAU00632 Idle speed adjustment 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Set the idle to the specified engine speed by adjusting the throttle stop screw Turn the screw in di rection a to increase engine s...

Page 76: ...wever should be left to a professional Yamaha service technician EAU01132 Tires To ensure maximum performance long service and safe operation note the following Tire air pressure Always check and adjust the tire pres sure before operating the motorcycle EW000082 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire i...

Page 77: ... 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 side wall is cracked con tact a Yamaha dealer immediately and have the tire replaced Ma...

Page 78: ...EW000080 WARNING After extensive tests the tires mentioned below have been ap proved by Yamaha Motor Co Ltd for this model No guaran tee for handling characteristics can be given if tire combina tions other than what is ap proved are used on this motorcycle The front and rear tires should be of the same manufacture and design The use of tire valves and valve cores other than listed below could cau...

Page 79: ...mance long service and safe operation note the following Always inspect the wheels before a ride Check for cracks bends or warpage of the wheels If any ab normal condition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced Tires and wheels should be bal anced whenever either one is changed or replaced Failu...

Page 80: ... adjusting nut at the crankcase in direction a to in crease free play or in direction b to decrease free play Then tight en the locknut 6 Install the cowling EAU00713 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly ad justed when the brake light comes on just before braking takes effect To ad just the rear brake light switch hold the switch...

Page 81: ...641 Rear brake A wear indicator groove is provided on each brake pad This indicator allows checking of brake pad wear without disassembling the brake Remove the rear caliper bolt and tilt the caliper for ward Inspect the groove If the groove has almost disappeared ask a Yamaha dealer to replace the pads Install the caliper and caliper bolt then tighten the bolt to the specified torque 1 Wear indic...

Page 82: ...e the rubber seals may deteriorate causing leakage and poor brake perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deterior...

Page 83: ...ery four years EAU00744 Drive chain slack check NOTE Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while it s in this tightest position To check the chain slack the motor cycle must be held straight up with both wheels on the ground and without rider Check the slack at the position shown in the illustration Normal slack is ap proximate...

Page 84: ...rive chain lubrication The chain consists of many parts which work with each other If the chain is not maintained properly it will wear out quickly Therefore the chain must be serviced regularly This service is es pecially necessary when riding in dusty areas This motorcycle is equipped with a sealed type chain Steam clean ing high pressure washers and sol vents can damage the drive chain so do no...

Page 85: ...e cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be re moved to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all pur...

Page 86: ...metal contact surfaces Check that the sidestand moves up and down smoothly EW000113 WARNING If the sidestand does not move smoothly consult a Yamaha dealer EAU00791 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Engine oil Recommended lubricant Engine oil Recommended lubricant Lithium soap base grease E_5eb_Periodic fm Page 31 Monday February 7 2000 9 04 AM ...

Page 87: ... smoothly EC000098 CAUTION If any damage or unsmooth move ment is found with the front fork consult a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be dangerous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward ...

Page 88: ...o discharge more quickly so be sure to recharge it periodically EW000116 WARNING Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quanti ties of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physi cian immediately EYES Flu...

Page 89: ...act your Yamaha dealer Always make sure the connec tions are correct when reinstall ing the battery EAU01754 Fuse replacement The fuse boxes are located under the rider seat If any fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of specified amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows agai...

Page 90: ...See page 6 8 for panel removal and installation procedures 2 Remove the headlight connector and the bulb holder cover 3 Unhook the bulb holder and re move the defective bulb Specified fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Radiator fan fuse 7 5 A Ignition fuse 15 A Odometer fuse 7 5 A 1 Connector 2 Bulb holder cover 1 Bulb holder E_5eb_Periodic fm Page 35 Monday Februa...

Page 91: ...ol or lac quer thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use headlight bulbs of wattage higher than speci fied 5 Install the bulb holder cover and reconnect the headlight connec tor If the headlight beam adjust ment is necessary ask a Yamaha dealer to make that adjustment EAU01823 Taillight bulb replacement 1 Remove the passenger seat See...

Page 92: ...to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability Front wheel service To stabilize the rear of the motorcycle either use a motorcycle stand or place a motorcycle jack under the frame in front of the rear wheel to prevent it from moving from side to side Then use a mot...

Page 93: ...d re move the wheel by pulling it back wards EAU01638 Front wheel installation 1 Lift up the wheel between the front fork legs 2 Install the wheel axle and let the motorcycle down 3 Push down hard on the handle bars several times to check for proper fork operation 4 Install the calipers caliper bolts and brake hose holders Make sure there is enough gap between the brake pads before installing the ...

Page 94: ... 4 Loosen the locknuts on each side of the swingarm 5 Turn the chain adjusting bolts fully inward 6 Push the wheel forward and re move the drive chain 7 Pull out the wheel axle and re move the wheel assembly by pull ing backwards NOTE Do not depress the brake pedal when the caliper is off the disc as the brake pads will be forced shut You do not have to disassemble the chain in order to remove or ...

Page 95: ... before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The trouble shooting chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to...

Page 96: ...is compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plugs Ask a Yamaha dealer to inspect Engine doesn t start ask a Yamaha dealer to inspect Engine doesn t start go to battery check Open throttle half way and start the engine Use the electric sta...

Page 97: ... pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recom mended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level ...

Page 98: ...E_5eb_Periodic fm Page 43 Monday February 7 2000 9 04 AM ...

Page 99: ...7 MOTORCYCLE CARE AND STORAGE Care 7 1 Storage 7 4 E_5eb_CleaningTOC fm Page 1 Monday February 7 2000 9 05 AM ...

Page 100: ...nd covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning After normal use Remove dirt wi...

Page 101: ...s since they cause water seepage and deterioration in the following ar eas seals of wheel bearings swingarm bearings forks and brakes electric components couplers connectors instru ments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may l...

Page 102: ...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 even chrome and nickel plated metal surfaces 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 compl...

Page 103: ...ty 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 several months 1 Follow all the instructions in the Care section of this chapter 2 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up ...

Page 104: ... 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 then raise 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 Cover up the muffler outlet with ...

Page 105: ...8 SPECIFICATIONS Specifications 8 1 HOW TO USE THE CONVERSION TABLE 8 5 E_5eb_SpecTOC fm Page 1 Monday February 7 2000 9 05 AM ...

Page 106: ...1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Periodic oil change 2 5 L With oil filter replacement 2 7 L Total amount 3 5 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 friction modifiers P...

Page 107: ...em Spur gear Primary reduction ratio 1 955 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 2 846 2nd 1 947 3rd 1 556 4th 1 333 5th 1 190 6th 1 083 Chassis Frame type Diamond Caster angle 24 Trail 81 mm Tire Type Tubeless Front Size 120 60 ZR17 55 W Manufacturer model Bridgestone BT56FE Dunlo...

Page 108: ...MT 3 50 Rear Type Cast Size 17 MT 5 50 Brakes Front Type Dual disc brake Operation Right hand operation Fluid DOT 4 Rear Type Single disc brake Operation Right foot operation Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Shock absorbers Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 130 mm Rear 120 mm Electrical system Ignitio...

Page 109: ...W 4 Meter light 12 V 1 4 W 2 Neutral indicator light LED High beam indicator light LED Turn indicator light LED Fuel indicator light LED Oil level coolant temperature indicator light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Radiator fan fuse 7 5 A Ignition fuse 15 A Odometer fuse 7 5 A E_5eb_Spec fm Page 4 Monday February 7 2000 9 06 AM ...

Page 110: ...PERIAL Metric 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 hr 0 6214 mph 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 lt liter lt liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Misc kg mm kg cm2 Centigrade C 5...

Page 111: ...ORMATION Identification number records 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 NOISE REGULATION For Australia 9 2 E_5eb_ConsumerTOC fm Page 1 Monday February 7 2000 9 06 AM ...

Page 112: ... EAU01041 Key identification number The key identification number is stamped on the key tag Record this number in the space provided and use it for reference when obtaining a new key EAU01043 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...

Page 113: ... 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 the vehicle after such ...

Page 114: ...dicator light 3 2 Fuel indicator light circuit check 3 6 Fuel tank cap 3 13 Fuse replacement 6 34 G Gasoline and exhaust gas 1 5 H Handlebar switches 3 9 Dimmer switch 3 9 Engine stop switch 3 10 Horn switch 3 10 Pass switch 3 9 Start switch 3 10 Turn signal switch 3 10 Headlight bulb replacement 6 35 Helmet holder 3 16 High beam indicator light 3 2 Horn switch 3 10 I Identification number records...

Page 115: ...6 31 Spark plug inspection 6 9 Specifications 8 1 Starter choke 3 14 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Start switch 3 10 Steering inspection 6 32 Storage 7 4 Storage compartment 3 16 Supporting the motorcycle 6 37 T Tachometer 3 8 Taillight bulb replacement 6 36 Throttle cable and grip lubrication 6 30 Throttle cable free play inspection 6 21 Tips for reducing fu...

Page 116: ...P_5jj_Periodic fm Page 45 Friday February 4 2000 10 27 AM ...

Page 117: ...PRINTED IN JAPAN 00 1 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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