Yamaha 5PW-28199-10 Owner'S Manual Download Page 65

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

EAU01139

Removing and installing
cowlings and panels

The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be re-
moved and installed.

1. Panel A
2. Cowling A
3. Cowling B

1. Panel B
2. Cowling B

U5PW10.book Page 8 Thursday, January 10, 2002 12:15 PM

Summary of Contents for 5PW-28199-10

Page 1: ...PRINTED IN JAPAN 2001 12 7 0 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5PW 28199 10 LIT 11626 15 47 YZF R1P YZF R1PC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...torcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these hig...

Page 4: ...e 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: ... TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ U5PW10 book Page 2 Thursday January 10 2002 12 15 PM ...

Page 6: ...001 by Yamaha Motor Corporation U S A 1st edition November 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 15 47 U5PW10 book Page 3 Thursday January 10 2002 12 15 PM ...

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 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 8: ...FORMATION 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 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 9: ...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 10: ...ering 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 foo...

Page 11: ...ion 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 motorc...

Page 12: ...e items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories U...

Page 13: ... therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical 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 the engine off when refueling b Take care not to spill ...

Page 14: ...ter or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the 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 clothi...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5PW10 book Page 7 Thursday January 10 2002 12 15 PM ...

Page 16: ... CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5LV 2835Y 00 5 2 PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 5PW 2415E 10 U5PW10 book Page 8 Thursday January 10 2002 12 15 PM ...

Page 17: ...SAFETY INFORMATION 1 1 9 8 9 10 U5PW10 book Page 9 Thursday January 10 2002 12 15 PM ...

Page 18: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 19: ...lt page 3 18 5 Front brake fluid reservoir page 6 31 6 Shock absorber assembly spring preload adjusting ring page 3 20 7 Shock absorber assembly compression damping force adjusting screw page 3 21 8 Owner s tool kit page 6 1 9 Shock absorber assembly rebound damping force adjusting screw page 3 21 10 Engine oil drain bolt page 6 14 11 Engine oil filter cartridge page 6 15 U5PW10 book Page 1 Thursd...

Page 20: ...lectronic fuel injection fuse page 6 40 16 Battery page 6 39 17 Rear brake fluid reservoir page 6 32 18 Air filter element page 6 21 19 Radiator cap page 6 18 20 Coolant reservoir page 6 18 21 Engine oil level check window page 6 14 22 Engine oil filler cap page 6 14 U5PW10 book Page 2 Thursday January 10 2002 12 15 PM ...

Page 21: ...2 Left handlebar switches page 3 11 3 Multi function display page 3 6 4 Main switch steering lock page 3 1 5 Tachometer page 3 11 6 Right handlebar switches page 3 12 7 Throttle grip page 6 23 8 Brake lever page 3 13 U5PW10 book Page 3 Thursday January 10 2002 12 15 PM ...

Page 22: ... Shift pedal 3 12 Brake lever 3 13 Brake pedal 3 13 Fuel tank cap 3 13 Fuel 3 14 Catalytic converter 3 15 Seats 3 15 Helmet holders 3 17 Storage compartment 3 17 Adjusting the front fork 3 18 Adjusting the shock absorber assembly 3 20 Luggage strap holders 3 23 EXUP system 3 23 Sidestand 3 23 Ignition circuit cut off system 3 24 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 23: ...nnot be re moved NOTE _ The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls _ EAU00038 OFF All electrical systems are off The key can be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the ...

Page 24: ...AU04303 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 3 L 0 73 lmp gal 0 87 US gal When this occurs refuel as soon as possible 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 for a few seconds then go off have a Yamaha dealer check the...

Page 25: ...r light comes on when the transmission is in the neutral position EAU04514 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this oc curs have a Yamaha dealer check the self diagnosis system NOTE _ This warning light comes on for a few seconds then goes off when the key is turned to ON but this does not indi cate ...

Page 26: ... EAU04515 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the key to ON 2 If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrica...

Page 27: ...flashes Warning 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 51 for further instructions Above 140 C 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See the Engine overheating sec tion on page 6 51 for further in st...

Page 28: ...ter and odometer tripmeter displays be tween kilometers and miles press the SELECT button and RESET button together for at least two seconds _ Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level warning light comes on see page 3 2 the odomet...

Page 29: ...tart flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Self diagnosis device This model is equipped with a self di agnosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning...

Page 30: ...hich the indicator light will be activated 4 Engine speed indicator light deac tivation This function allows you to select the engine speed at which the indicator light will be de activated 5 Engine speed indicator light brightness This function allows you to adjust the brightness of the indicator light to suit your prefer ence NOTE _ To make any settings in this mode you have to cycle through all...

Page 31: ...r light will flash when activated This setting is selected when the indicator light flashes four times per second c The indicator light is deactivated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to con firm the selected indicator light ac tivity The control mode changes to the engine speed ind...

Page 32: ... Push the RESET button to select the desired engine speed for de activating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the engine speed indicator light bright ness function To adjust the engine speed indicator light brightness 1 Push the RESET button to select the desired indicator light bright ness level 2 Push the SELECT button ...

Page 33: ... this switch to for the high beam and to for the low beam EAU03889 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn 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 1 Tacho...

Page 34: ...isengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 24 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is l...

Page 35: ... EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU04068 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into ...

Page 36: ... warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION _ Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts _ EAU04567 ECA00104 CAUTION _ Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaus...

Page 37: ...em or ve hicle performance problems EAU03098 Catalytic converter This motorcycle is equipped with a cat alytic converter in the muffler EW000128 WARNING _ The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work _ EC000114 CAUTION _ The following precautions must be observed to prevent a fire hazard or other damages Use only un...

Page 38: ...terclockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projections on the rear of the passenger seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key NOTE _ Make sure that the seats are properly secured before riding _ 1 Projection 2 Seat ho...

Page 39: ...he muf fler when secured to the right side helmet holder because of their size or shape Be sure that your helmet does not contact the muffler when it is secured to the helmet holder _ To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU01242 Storage compartment The storage compartment is located under the passenge...

Page 40: ...pring 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 adjusting bolt on each fork leg in direction b NOTE _ Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt _ CI 10E 1 Spring preload adjusting bo...

Page 41: ...sm beyond the maximum or minimum settings _ NOTE _ Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justi...

Page 42: ...spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE _ Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment _ CI 10E 1 Spring ...

Page 43: ...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 44: ...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 45: ...sted 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 technical knowledge may result in poor performance of or dam age to the engine If the EXUP system does not op erate have a Yamaha dealer check it _ EAU00330 Sidestand The sidestand is loc...

Page 46: ...ction 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 trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the si...

Page 47: ... 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 should...

Page 48: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 49: ...age 6 13 6 14 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 17 6 18 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 30 6 32 Rear brake Check opera...

Page 50: ...dition and tread depth Check air pressure Correct if necessary 6 24 6 27 Shift pedal Make sure that operation is smooth Correct if necessary Brake pedal Make sure that operation is smooth Lubricate brake pedal pivoting point if necessary 6 36 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 35 6 36 Sidestand Make sure that operation is smoot...

Page 51: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Shifting 5 3 Engine break in 5 4 Parking 5 5 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 52: ...control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04568 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starti...

Page 53: ...the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 3 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine mor...

Page 54: ...ile changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At...

Page 55: ...re shown in the table below CF 05E 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 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them selves to t...

Page 56: ...he engine break in period immediately have a Yamaha dealer check the vehi cle _ NOTE _ During and after the engine break in period the exhaust heat may cause discoloration of the exhaust pipe but this is normal _ EAU00461 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING _ Since the engine and exhaust system can become very hot park in a place where...

Page 57: ...ke light switch 6 29 Checking the front and rear brake pads 6 30 Checking the brake fluid level 6 31 Changing the brake fluid 6 32 Drive chain slack 6 33 Lubricating the drive chain 6 34 Checking and lubricating the cables 6 35 Checking and lubricating the throttle grip and cable 6 35 Checking and lubricating the brake and clutch levers 6 35 Lubricating the brake pedal 6 36 Checking and lubricatin...

Page 58: ...HE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO ...

Page 59: ...particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ U5PW10 book Page 2 Thursday January 10 2002 12 15 PM ...

Page 60: ...lve clearance when engine is cold Every 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses and vacuum hose for cracks or damage Replace if necessary 5 Exhaust system Check for leakage Retighten...

Page 61: ...or damage Replace if necessary 8 Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months U5PW10 book Page 4 ...

Page 62: ...r every 8 000 mi 13 000 km or 12 months 3 Air filter element Check condition Replace if necessary 4 Cooling system Check hoses for cracks or damage Replace if necessary Replace with ethylene glycol anti freeze coolant every 24 months Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 7 Correct if necessary 6 Clutch Check operation Adjust or replace cable 7 Control...

Page 63: ...r lithium soap based grease lightly 15 Drive chain Check chain slack alignment condition Adjust and lubricate chain with Yamaha chain and cable lube or engine oil SAE10W 30 thoroughly Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 16 Wheel bearings Check bearings for smooth operation 17 Sidestand pivot Check operation Apply chain lube or lithium soap based grease light...

Page 64: ...s always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required 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 Engine oil type Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above Yamalube 4...

Page 65: ...ings and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed 1 Panel A 2 Cowling A 3 Cowling B 1 Panel B 2 Cowling B U5PW10 book Page 8 Thursday January 10 2002 12 15 PM ...

Page 66: ...isconnect the turn signal light lead coupler 5 Remove the screws and then take the cowling off To install the cowling 1 Install the screws 2 Connect the turn signal light lead coupler 3 Place the cowling in the original position 4 Install the screw and the bolts tighten the quick fastener screws and then install the quick fasten ers 1 Quick fastener 4 1 Quick fastener screw 6 2 Screw 3 Bolt 2 1 Tu...

Page 67: ...wling B To remove the cowling Remove the bolts loosen the quick fas tener 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 bolts 1 Quick fastener After removal Before installation 1 Quick fastener screw 4 2 Cowling B 3 Bolt Right side 1 Bolt 2 Quick fastener ...

Page 68: ...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 installed in the engine should have the same color If any spark plug shows a distinctl...

Page 69: ... 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 8 0 9 mm 0 03 0 04 in Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft lb...

Page 70: ...ked and if nec essary clean it EAU04279 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ M...

Page 71: ... it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Remove cowling B See page 6 10 for cowling removal and installation procedures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NO...

Page 72: ...t the O ring is properly seated _ 7 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and then tighten it to the specified torque 1 Oil filter wrench 2 Oil filter cartridge 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 43 Nm 4 3...

Page 73: ...l 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 _ EC000067 CAUTION _ If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle _ 11 Turn the engine off and then check the oil le...

Page 74: ...nel A See page 6 11 for panel removal and installation procedures re move the reservoir cap add cool ant to the maximum level mark and then install the reservoir cap and the panel EC000080 CAUTION _ If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with...

Page 75: ...procedures 3 Place a container under the en gine to collect the used coolant 4 Remove the radiator cap and cool ant reservoir cap EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot __ 5 Remove the clutch cable holder from the coolant reservoir as shown 6 Remove the coolant reservoir by removing the bolts and then turn the coolant reservoir upside down to empty it 7...

Page 76: ...k the washer for damage and re place it if necessary _ 12 Connect the radiator hose and then tighten the clamp screw 13 Pour the specified amount of rec ommended coolant into the radia tor and reservoir 1 Coolant drain bolt 2 Clamp screw Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze ...

Page 77: ...be reduced _ 14 Install the radiator cap and the coolant reservoir cap and then start the engine and let it idle for several minutes During this peri od rev the engine two or three times between 3 000 5 000 r min and then turn it off 15 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 t...

Page 78: ...he bolt 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 Disconnect the fuel tank breather hose and the fuel tank overflow hose 5 Remove the a...

Page 79: ... be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 8 Install the air filter case cover by installing the screws and bolt 9 Connect the fuel tank breather hose and the fuel tank overflow hose place the fuel tank in the original position and then install the bolt 1 Air filter element 1 Fuel tank breather hose 2 Fuel tank overf...

Page 80: ...r seat EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 1 0 2 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring...

Page 81: ...loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if approv...

Page 82: ...en a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience _ Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Sidewall 2 Tire wear indicator a Tire...

Page 83: ...nt 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 riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire The tires must be warm...

Page 84: ...evelop its optimal characteris tics EAU00691 Accessories and replacement parts EW000098 WARNING _ This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Ya...

Page 85: ... 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 B See page 6 10 for cowling removal and installation 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 p...

Page 86: ...ydraulic 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...

Page 87: ...e point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04396 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake Check the brake pad wear as follows 1 Remove the brake caliper bolt and then tilt the caliper forward to inspect...

Page 88: ...eck 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 causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemica...

Page 89: ...l to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the inte...

Page 90: ...motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU03608 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive ch...

Page 91: ...e 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 EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging the O rings do not clean the dr...

Page 92: ...es as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clut...

Page 93: ... operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING _ If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it _ Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose gre...

Page 94: ...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 does not operate smoothly have a Yamaha dealer check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be c...

Page 95: ...a dealer check or repair the steer ing 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 If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5PW10 book Page 38 Thursday January 10 2002 12 15 PM ...

Page 96: ...g 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 AND A...

Page 97: ...res The fuse box which contains the fuses for the individual circuits is located un der panel B See page 6 11 for panel 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 Signaling system fuse 3 Ignition fus...

Page 98: ...ce operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU04503 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight bulb cove...

Page 99: ...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 than speci fied _ 4 Install the headlight bulb cover and then connect the coupler 5 Have a ...

Page 100: ...ounter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 CAUTION _ Do not overtighten the screw other wise the lens may break _ EAU04574 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 1 Screw 1 Screw 2 U5PW10 book Page 43 Thursday January 10 200...

Page 101: ...s in a stable and level position before starting any maintenance A strong wooden box can be placed un der 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 mot...

Page 102: ...cording to the procedure on page 6 44 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper and re flector on each side by removing the bolts 5 Remove the axle bolt 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 the brake pads will be forced shut _ 1 Front...

Page 103: ...d the wheel axle with a 19 mm hexagon wrench to keep it from turning _ 7 Tighten wheel axle pinch bolts A and B to the specified torque 8 Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle 9 Tighten wheel axle pinch bolts C and D to the specified torque 10 While applying the front brake push down hard on the handlebar several times to check for...

Page 104: ...edure on page 6 44 3 Remove the axle nut and then re move the brake caliper by remov ing the bolts 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a 6 Push the 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 _ ...

Page 105: ...side NOTE _ Make sure that there is enough space between the brake pads before install ing the wheel _ 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 33 for drive chain slack adjustment pro cedures 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Install the brake caliper by install ing the bolts 5 Tighten the axl...

Page 106: ...troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 107: ...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 starter 4 Batt...

Page 108: ...ng sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ CT 2AE 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 ...

Page 109: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 110: ...htly 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 rem...

Page 111: ...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 ridin...

Page 112: ...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 Use...

Page 113: ...00014 CAUTION _ Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust 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...

Page 114: ...ng the engine over _ 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 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 6 Cover the ...

Page 115: ...SPECIFICATIONS 8 Specifications 8 1 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 116: ...m Electric 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 9 L 2 55 lmp qt 3 07 US qt With oil filter cartridge replacement 3 1 L 2 73 lmp qt 3 28 US qt Total amount dry engine 3 8 L 3 34 lmp qt 4 02 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0 10...

Page 117: ...ansmission Primary reduction system Spur gear Primary 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 103 mm 4 06 in Tire...

Page 118: ...t wheel Size 17 M C MT 3 50 Rear Type Cast wheel Size 17 M C 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 120 mm 4 72 in Rear 130 mm 5 12 in Ele...

Page 119: ... Neutral indicator light L E D High beam indicator light L E D Turn signal indicator light L E D Fuel level warning light L E D Oil level warning light L E D Engine trouble warning light L E D Engine speed indicator light L E D Fuses Main fuse 50 A Headlight fuse 20 A Signaling system fuse 15 A Radiator fan fuse 15 A Ignition fuse 15 A Backup fuse odometer and clock 5 A Electronic fuel injection f...

Page 120: ...entification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5PW10 book Page 1 Thursday January 10 2002 12 15 PM ...

Page 121: ...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 pro vided NOTE _ The vehicle identification number is used to identify yo...

Page 122: ... the passenger seat See page 3 16 for passenger seat removal and installation procedures Record the in formation on this label in the space pro vided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5PW10 book Page 2 Thursday January 10 2002 12 15 PM ...

Page 123: ...tigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tran...

Page 124: ...for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 01E...

Page 125: ...rinted only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi 3...

Page 126: ...r 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5PW10 book Page 6 Thursday January 10 2002 12 15 PM ...

Page 127: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5PW10 book Page 7 Thursday January 10 2002 12 15 PM ...

Page 128: ...CONSUMER INFORMATION 9 8 9 U5PW10 book Page 8 Thursday January 10 2002 12 15 PM ...

Page 129: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S U5PW10 book Page 9 Thursday January 10 2002 12 15 PM ...

Page 130: ...CONSUMER INFORMATION 9 10 9 U5PW10 book Page 10 Thursday January 10 2002 12 15 PM ...

Page 131: ...break in 5 4 Engine oil and oil filter cartridge 6 13 Engine speed indicator light 3 4 Engine stop switch 3 12 Engine trouble warning light 3 3 EXUP system 3 23 F Front fork adjusting 3 18 Front fork checking 6 37 Fuel 3 14 Fuel level warning light 3 2 Fuel tank cap 3 13 Fuses replacing 6 40 H Handlebar switches 3 11 Headlight bulb replacing 6 41 Helmet holders 3 17 High beam indicator light 3 3 H...

Page 132: ...cking 6 37 Storage 7 4 Storage compartment 3 17 Supporting the motorcycle 6 44 T Tachometer 3 11 Tail brake light 6 42 Throttle cable free play adjusting 6 23 Throttle grip and cable checking and lubricating 6 35 Tires 6 24 Tool kit 6 1 Troubleshooting 6 49 Troubleshooting charts 6 50 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 43 Turn signal switch 3 11 V Valve clearance a...

Page 133: ...PRINTED IN JAPAN 2001 12 7 0 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5PW 28199 10 LIT 11626 15 47 YZF R1P YZF R1PC OWNER S MANUAL ...

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