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Yamaha 2007 YZF-R6W Owner'S Manual Download Page 55

PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

6

●

Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake

fluid.

• Replace the brake hoses every four years and if cracked or damaged.

U2C021E0.book  Page 5  Friday, July 7, 2006  4:11 PM

Summary of Contents for 2007 YZF-R6W

Page 1: ...2C0 28199 21 YZF R6W OWNER S MANUAL ...

Page 2: ...U2C021E0 book Page 2 Friday July 7 2006 4 11 PM ...

Page 3: ...as to enjoy all advantages of your YZF R6W The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha d...

Page 4: ...l If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or dea...

Page 5: ... MANUAL 2006 by Yamaha Motor Co Ltd 1st edition July 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2C021E0 book Page 2 Friday July 7 2006 4 11 PM ...

Page 6: ...Periodic maintenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 6 Checking the spark plugs 6 10 Engine oil and oil filter cartridge 6 11 Coolant 6 14 Air filter element 6 17 Checking the throttle cable free play 6 18 Valve clearance 6 18 Tires 6 18 Cast wheels 6 21 Adjusting the clutch lever free play 6 21 Adjusting the rear brake light switch 6 22 Checking the front a...

Page 7: ... 6 37 Rear wheel 6 39 Troubleshooting 6 40 Troubleshooting charts 6 41 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 For solo riding 9 2 Motorcycle noise regulation for Australia 9 2 U2C021E0 book Page 2 Friday July 7 2006 4 11 PM ...

Page 8: ...ents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other m...

Page 9: ...shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or...

Page 10: ...s 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 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 clea...

Page 11: ...d equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2C021E0 book Page 5 Friday July 7 2006 4 11 PM ...

Page 13: ... manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 01 Cold tire normal pressure should be set as follows U2C021E0 book Page 6 Friday July 7 2006 4 11 PM ...

Page 14: ... 6 Shock absorber assembly compression damping force adjusting screw for slow compression damping page 3 22 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 22 9 Shift pedal page 3 15 10 Engine oil drain bolt page 6 11 11 Engine oil filter cartridge page 6 11 12 Front fork compression damping force adjusting bolt for fast compres sion damping page ...

Page 15: ...m fuse page 6 32 6 Battery page 6 30 7 Air filter element page 6 17 8 Front brake fluid reservoir page 6 23 9 Radiator cap page 6 14 10 Coolant reservoir page 6 14 11 Engine oil filler cap page 6 11 12 Coolant drain bolt page 6 15 13 Dipstick page 6 11 14 Brake pedal page 3 16 15 Rear brake fluid reservoir page 6 23 U2C021E0 book Page 2 Friday July 7 2006 4 11 PM ...

Page 16: ... lever page 3 14 2 Left handlebar switches page 3 13 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 7 5 Right handlebar switches page 3 13 6 Brake lever page 3 15 7 Throttle grip page 6 18 U2C021E0 book Page 3 Friday July 7 2006 4 11 PM ...

Page 17: ...T IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re regis ...

Page 18: ...lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed NOTE The headlight comes on automatically when the engine is started and stays 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 o...

Page 19: ... systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right 1...

Page 20: ...s If this occurs have a Yamaha dealer check the vehicle EAU11361 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 5 L 0 92 US gal 0 77 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds and then go off have ...

Page 21: ...INSTRUMENT AND CONTROL FUNCTIONS 3 5 3 CAUTION ECA10020 Do not operate the engine if it is overheated U2C021E0 book Page 5 Friday July 7 2006 4 11 PM ...

Page 22: ... OK Go ahead with riding 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 41 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 41 U2C021E0 book Page 6 Friday July 7 2006 4 1...

Page 23: ...tion of this indicator light and on how to set it EAU38620 Immobilizer system indicator light The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing in...

Page 24: ...tric 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 CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 16500 r min and above Clock mode Turn the key to ON To s...

Page 25: ...lly and the display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SE LECT button The stopwatch digits will start flashing Release the SE LECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the sto...

Page 26: ...urned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed before the temperature Self diagnosis devices This model is equipped with a self diag nosis device for various electrical cir cuits If any of those circuits are defective the engine troubl...

Page 27: ...rightness and shift timing indicator light control mode This mode cycles through five control functions allowing you to make the fol lowing settings in the order listed be low Display brightness This function allows you to adjust the brightness of the displays and tachometer to suit the outside lighting conditions Shift timing indicator light activity This function allows you to choose whether or ...

Page 28: ...me on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to con firm the selected indicator light ac tivity The control mode changes to the shift timing indicator light acti vation function To set the shift timing indicator light ac tivation function NOTE The shift timing indicator light activation function can be set between 10000 r ...

Page 29: ... to select the desired indicator light bright ness level 2 Push the SELECT button to con firm the selected indicator light brightness level The right display will return to the odometer or trip meter mode EAU12347 Handlebar switches Left Right EAU12350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 T...

Page 30: ...t indicate a malfunction EAU12733 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10061 Do not use the hazard lights for an extended length of time with ...

Page 31: ...ke pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting knob To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting knob while holding the lever pushed away from the handlebar grip When the de sired position is obtained be sure to set it by aligning a groove on the adjusting knob with the mark on the brake lever 1 Shift...

Page 32: ...el 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 WARNING EWA11090 Make s...

Page 33: ... EAU13390 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use premium unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of unleaded...

Page 34: ... converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU39030 Seats Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as sho...

Page 35: ...is provided in the owner s tool kit to secure two hel mets to the helmet cable holder equipped on the bottom of the passen ger seat To secure a helmet with the helmet holding cable 1 Remove the passenger seat See page 3 18 2 Clip the middle snap hook of the cable onto the cable holder 3 Pass one of the other snap hooks of the cable through the helmet strap buckle and then clip the snap hook onto t...

Page 36: ...g force adjusting screws and com pression damping force adjusting bolts WARNING EWA10180 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 load and thereby soften the suspension turn the adju...

Page 37: ...lt on each fork leg in direction b NOTE The compression damping force set ting is determined by measuring dis tance A shown in the illustration The longer distance A is the higher the compression damping force the short er distance A is the lower the compres sion damping force 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 17 click s in direction b Standard 15 click s...

Page 38: ...umber 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 EAU38951 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and rebound and compression damping forc...

Page 39: ...n the adjusting screw in di rection b Compression damping force Compression damping force for fast compression damping To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw in direction a To decrease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b Spring preload setting Minimu...

Page 40: ... 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 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 pressu...

Page 41: ...em This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor CAUTION ECA15610 The EXUP system has been set and extensively tested at the Yamaha factory Changing ...

Page 42: ...ng the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tr...

Page 43: ...ter 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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle ...

Page 44: ...sequences 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 WARNING EWA11150 If any item in the Pre operation check list is not...

Page 45: ... soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in rese...

Page 46: ...cessary 6 18 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tigh...

Page 47: ...estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 26 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11730 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warnin...

Page 48: ...n 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 CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine...

Page 49: ...efully 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 8300 r min 1000 ...

Page 50: ...the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U2C021E0 book Page 4 Friday July 7 2006 4 11 PM ...

Page 51: ...re not familiar with mainte nance work have a Yamaha dealer do it for you EAU17541 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 18 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 w...

Page 52: ...ER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check...

Page 53: ...bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage ...

Page 54: ... 3 years 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 28 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damaged parts if necessary 29 Muffler and exhaus...

Page 55: ...ck and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U2C021E0 book Page 5 Friday July 7 2006 4 11 PM ...

Page 56: ...e a cowling or panel needs to be re moved and installed EAU38970 Cowlings A and B To remove one of the cowlings Remove the bolts and the quick fasten er and then pull the cowling off as shown To install the cowling 1 Fit the tabs on the cowling into the slots and slide it backward 1 Cowling A 2 Cowling C 1 Cowling B 2 Cowling D 3 Cowling E 1 Panel A 2 Panel B 1 Cowling A 2 Bolt 3 Quick fastener U2...

Page 57: ...cowling B if remov ing cowling D See page 6 6 2 Disconnect the turn signal light lead coupler 3 Remove the bolts quick fasteners and quick fastener screw and then take the cowling off 1 Cowling A 2 Tab 3 Slot 1 Cowling B 2 Tab 3 Slot 1 Cowling C 2 Bolt 3 Turn signal light lead coupler 4 Quick fastener 1 Quick fastener 1 Quick fastener screw U2C021E0 book Page 7 Friday July 7 2006 4 11 PM ...

Page 58: ...wl ing B to complete the installation of cowling D EAU39091 Cowling E To remove the cowling 1 Remove cowling B and panel B See page 6 6 2 Unfasten the wire harness by pressing on the tab to open the plastic fastener 3 Remove the bolts and the quick fastener and then pull the cowling off as shown 1 Cowling D 2 Bolt 3 Turn signal light lead coupler 4 Quick fastener 1 Quick fastener 1 Quick fastener ...

Page 59: ...position and then close the plastic fastener 4 Install the cowling and the panel EAU39060 Panels A and B To remove one of the panels Remove the bolts and then pull the panel off as shown To install the panel Place the panel in the original position and then install the bolts 1 Cowling E 2 Bolt 3 Quick fastener 1 Cowling E 2 Slot 3 Front cowling 4 Tab 1 Panel B 2 Bolt U2C021E0 book Page 9 Friday Ju...

Page 60: ...excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its mating 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 esti...

Page 61: ... wipe it clean insert it back into the hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark remove the oil filler cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the engine oil dipsti...

Page 62: ... An oil filter wrench is available at a Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt 1 Bolt 2 Shift arm 3 Engine oil filter cartridge 4 Guide 5 Fu...

Page 63: ... specified amount of the recommended engine oil and then install and tighten the oil filler cap CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 Torq...

Page 64: ...h ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU39084 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 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 c...

Page 65: ... the panel NOTE 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 41 for further instructions EAU39002 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove cowlings D and E See page 6 6 3 Place a container under the engine to collect the used coolant...

Page 66: ...nd re place it if necessary 13 Pour the recommended coolant into the reservoir to the maximum level mark and then install the coolant reservoir cap 14 Pour the recommended coolant into the radiator until it is full 1 Coolant drain bolt 2 Hose clamp 3 Radiator hose 1 Coolant reservoir cap 2 Coolant reservoir 3 Bolt Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mix...

Page 67: ...ness of the coolant will be reduced 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 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 17 Start the engine and then check the vehicle for coolant leakage If coolant is le...

Page 68: ...specified in the periodic maintenance and lubrication chart EAU21780 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 WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e whe...

Page 69: ...s 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 WARNING EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and br...

Page 70: ...s motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed r...

Page 71: ...tics EAU33890 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free play turn the adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE If th...

Page 72: ...c ified in the periodic maintenance and lubrication chart EAU36890 Front brake pads 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 the point that a wear indicator almost touches the bra...

Page 73: ...the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid ...

Page 74: ...d be checked before each ride and adjusted if necessary EAU22772 To check the drive chain slack 1 Place the motorcycle on the side stand NOTE When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then meas...

Page 75: ...i fied torque 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 CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in t...

Page 76: ...If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be check...

Page 77: ...the pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U2C021E0 book Page 27 Friday July 7 2006 4 11 PM ...

Page 78: ... sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubric...

Page 79: ... to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it 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 the pe riodic maintenance and lubric...

Page 80: ...need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes se...

Page 81: ...n a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery dam...

Page 82: ...y a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 1 Main fuse 2 Fuel injection system spare fuse 3 Fuel injection system fuse 4 Fuse box 1 5 Spare fuse 6 ETV electric throttle valve fuse 7 Backup fuse for odometer clock and immo bilizer system 1 Fuse box 2 2 Right radiator fan fuse 3 Left radiator fan fuse 4 Signaling system fuse 5 Ignitio...

Page 83: ...ise 2 Disconnect the headlight coupler 3 Unhook the headlight bulb holder and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the...

Page 84: ...r thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Connect the headlight coupler 6 Install the headlight bulb cover by turning it clockwise 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24180 Tail brake light This model is equipped with an LED type of tail brake light If...

Page 85: ...N ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the li...

Page 86: ...ng any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise t...

Page 87: ... brake caliper on each side by removing the bolts 5 Remove the axle bolt push the wheel axle out from the left side and then remove the wheel CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut EAU33932 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so t...

Page 88: ...ue 9 Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle 10 Tighten wheel axle pinch bolt D and then tighten pinch bolt C to the specified torque 11 Retighten pinch bolt D to the spec ified torque 12 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bol...

Page 89: ...rear sprocket NOTE If 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 CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with t...

Page 90: ...tory 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 exper...

Page 91: ...on There is no compression 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 The engine does not start Check the battery Operate the electric st...

Page 92: ...pped 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 the cooling system for ...

Page 93: ...over the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly 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 ...

Page 94: ...r 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 c...

Page 95: ... recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed 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 completely before storing or covering it WARNING EWA11130 Make sure that there is no oil or wax on the brakes or tire...

Page 96: ...at 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 WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning...

Page 97: ... cartridge replacement 2 60 L 2 75 US qt 2 29 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 30 L 2 43 US qt 2 02 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 5 L 4 62 US gal 3 85 Imp gal Fuel reserve amoun...

Page 98: ...ront 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 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right ...

Page 99: ...or light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 7 5 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator ...

Page 100: ...entification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 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 ...

Page 101: ... or remove these covers and make any changes in the registration documentation for rider ca pacity if necessary EAU26570 Motorcycle noise regulation for Australia TAMPERING 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 de...

Page 102: ... 14 Headlight bulb replacing 6 33 Helmet holding cable 3 19 High beam indicator light 3 4 Horn switch 3 14 I Identification numbers 9 1 Ignition circuit cut off system 3 26 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 35 Luggage strap holders 3 25 M Main s...

Page 103: ...0 Troubleshooting charts 6 41 Turn signal indicator lights 3 3 Turn signal light bulb replacing 6 35 Turn signal switch 3 13 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheel front 6 37 Wheel rear 6 39 Wheels 6 21 U2C021E0 book Page 2 Friday July 7 2006 4 11 PM ...

Page 104: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 105: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 106: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 07 0 4 1 CR E ...

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