Yamaha Diversion 900 Owner'S Manual Download Page 63 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6

EAU00687

Wheels

To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

●

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

●

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

●

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it to
develop its optimal characteristics.

EAU00694

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the clutch

lever.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection

a

. To decrease the clutch

lever free play, turn the adjusting
bolt in direction

b

.

3. If the specified clutch lever free

play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the

clutch lever in direction

a

to loos-

en the clutch cable.

5. Loosen the locknut at the

crankcase.

6. To increase the clutch lever free

play, turn the adjusting nut in di-
rection

a

. To decrease the clutch

lever free play, turn the adjusting
nut in direction

b

.

7. Tighten the locknut at the clutch

lever and the crankcase.

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

1. Locknut
2. Clutch lever free play adjusting nut

E_4km.book Page 20 Thursday, September 7, 2000 9:32 AM

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Summary of Contents for Diversion 900

Page 1: ...4KM 28199 E6 OWNER S MANUAL XJ900S ...

Page 2: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 3: ...o enjoy all advantages of your XJ900S 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 oth ers 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 deale...

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

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_4km book Page 2 Thursday September 7 2000 9 32 AM ...

Page 6: ...NUAL 2000 by Yamaha Motor Co Ltd 1st Edition June 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4km book Page 3 Thursday September 7 2000 9 32 AM ...

Page 7: ...NT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 8: ...E_4km book Page 2 Thursday September 7 2000 9 32 AM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however should...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 12: ...ht page 6 30 2 Helmet holder page 3 11 3 Seat lock page 3 11 4 Luggage strap holders 5 Final gear case page 6 11 6 Rear shock absorber spring preload adjusting ring page 3 14 7 Shift pedal page 3 8 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 13: ... page 6 29 10 Seat page 3 11 11 Owner s tool kit page 6 1 12 Air filter element page 6 13 13 Front fork spring preload adjusting bolt page 3 13 14 Engine oil level check window page 6 8 15 Brake pedal page 3 8 E_4km book Page 2 Thursday September 7 2000 9 32 AM ...

Page 14: ...3 6 3 Starter choke lever page 3 10 4 Speedometer unit page 3 3 5 Tachometer page 3 4 6 Fuel gauge page 3 5 7 Clock page 3 5 8 Right handlebar switches page 3 7 9 Brake lever page 3 8 10 Throttle grip page 6 16 11 Main switch steering lock page 3 1 E_4km book Page 3 Thursday September 7 2000 9 32 AM ...

Page 15: ...Handlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose for Germany only 3 10 Starter choke lever 3 10 Seat 3 11 Helmet holder 3 11 Storage compartment 3 12 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 13 Sidestand 3 15 Ignition circuit cut off system 3 15 E_4km book Page 1 Thursday Septembe...

Page 16: ...d 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 key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the motorcycle is movin...

Page 17: ...r right EAU03680 Fuel level warning light This warning light comes on when the fuel level drops below approximately 5 L 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 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push ...

Page 18: ...the electri cal circuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU00094 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter sho...

Page 19: ...ly display the following error code CB 17E Use the table below to identify the faulty electrical circuit CB 18E If the tachometer displays such an er ror code note the circuit specific num ber of r min and then have a Yamaha dealer check the motorcycle EC000004 CAUTION When the tachometer displays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage 1 ...

Page 20: ...k If this occurs refuel as soon as possible NOTE Do not allow the fuel tank to empty it self completely EAU00117 Clock The digital clock shows the time re gardless of the main switch position To set the clock 1 Turn the key to ON 2 Push or hold the hour setting but ton H to change the hours 3 Push or hold the minute setting button M to change the minutes NOTE To set the clock after the battery has...

Page 21: ...not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU00127 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 th...

Page 22: ...5 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which ...

Page 23: ... The brake lever is equipped with a posi tion adjusting nut To adjust the distance between the brake lever and the han dlebar grip turn the adjusting nut while holding the lever pushed away from the handlebar grip Make sure that the mark on the adjusting nut is aligned with the mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear bra...

Page 24: ...TE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding EAU01183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration EW000130 WARNING D...

Page 25: ...el tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary EAU02976 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move t...

Page 26: ... the rear of the seat down to lock it in place and then remove the key NOTE Make sure that the seat is properly se cured before riding EAU00263 Helmet holder The helmet holder is located under the seat To secure a helmet to the helmet holder 1 Remove the seat 2 Attach the helmet to the helmet holder and then securely install the seat 1 Seat lock 2 Unlock 1 Projection 2 2 Seat holder 1 Helmet holde...

Page 27: ...artment is designed to hold a genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage compartment securely fasten it with the straps When the U LOCK is not in the storage com partment be sure to secure the straps to prevent losing them When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will no...

Page 28: ... 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 01E EAU00295 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring EC000015 CAUTION Never attempt to turn an adjusting mechan...

Page 29: ...stand the following information be fore 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 pressure Do not deform or dam...

Page 30: ... cut off system has been designed to assist the operator in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly EAU00332 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral sw...

Page 31: ...IONS 3 16 3 EW000046 WARNING The vehicle must be placed on the centerstand during this inspection If a malfunction is noted have a Yamaha dealer check the sys tem before riding E_4km book Page 16 Thursday September 7 2000 9 32 AM ...

Page 32: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 33: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 34: ...e 6 8 Final gear oil Check vehicle for oil leakage 6 11 6 12 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 21 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservo...

Page 35: ...7 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Ti...

Page 36: ...E_4km book Page 3 Thursday September 7 2000 9 32 AM ...

Page 37: ... Starting a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 38: ...nable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 17 Never ride with the sidestand down 1 Turn the key to ON and make ...

Page 39: ...engine oil have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on when pushing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer che...

Page 40: ...n press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 41: ...e shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU00436 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 000 km For this rea son you should read the following ma teri...

Page 42: ...nd final gear oil must be changed and the oil filter cartridge replaced 1 000 km and beyond The vehicle can now be operated normally EC000053 CAUTION Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00460 Parking When parking stop the engine and then remove the key from t...

Page 43: ...ar brake light switch 6 21 Checking the front and rear brake pads 6 21 Checking the brake fluid level 6 22 Changing the brake fluid 6 23 Checking and lubricating the cables 6 23 Checking and lubricating the throttle grip and cable 6 23 Checking and lubricating the brake and shift pedals 6 24 Checking and lubricating the brake and clutch levers 6 24 Checking and lubricating the centerstand and side...

Page 44: ...cycle maintenance work have a Yamaha dealer do it for you EAU03394 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 11 for rider seat removal and installation proce dures 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 add...

Page 45: ...CK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 20 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to...

Page 46: ...crews are properly tightened 16 Sidestand centerstand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Rear shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with molybdenum disulfide grease 21 Carburetors Check starter...

Page 47: ...place the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 ...

Page 48: ...oved and installed EAU03595 Cowling A To remove the cowling 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Remove the screws and then pull the cowling off as shown NOTE Pull the cowling up then back to re move it To install the cowling 1 Place the cowling in the original position and then install the screws 2 Install the seat 1 Cowling A 2 Cowling B 1 Cowling A 2 Sc...

Page 49: ...res 2 Remove the grab bar by removing the bolts 3 Remove the screws and then pull the cowling off as shown To install the cowling 1 Place the cowling in the original position and then install the screws 2 Install the grab bar by installing the bolts 3 Install cowling A 1 Grab bar 2 Cowling B 1 Bolt 2 1 Screw 2 E_4km book Page 6 Thursday September 7 2000 9 32 AM ...

Page 50: ... spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark ...

Page 51: ...e oil level 1 Place the motorcycle on the cen terstand NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right si...

Page 52: ...ect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 1 Engine oil filler cap 1 Engine oil drain bolt 1 Oil filter cartridge 2 Oil filter wrench E_4km book Page 9 ...

Page 53: ...es with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level ...

Page 54: ...pair the motorcycle In addition the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart EW000066 WARNING _ Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel _ To check the final gear oil level 1 Place the motorcycle on the cen terstand NOTE _ The final gear oil level must...

Page 55: ...the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque 4 Add the recommended final gear oil to the brim of the filler hole NOTE _ GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used _ 5 Install and tighten the filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Final gear oil filler ...

Page 56: ...in unusually wet or dusty areas 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Turn the fuel cock lever to OFF and then disconnect the fuel hose 3 Remove the fuel tank bolts 4 Disconnect the fuel sender cou pler and then take the fuel tank off 5 Remove the air filter case cover by removing the screws 1 Fuel tank 2 Fuel hose 3 Fuel sender coupler 4 Fuel cock lever 1 ...

Page 57: ... Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by installing the screws 10 Connect the fuel sender coupler and then install the fuel tank by in stalling the bolts 11 Connect the fue...

Page 58: ... Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 5 000 r min NOTE The engine is warm when it quickly re sponds to the throttle 2 Check the engine...

Page 59: ...hrottle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it a Throttle cable free play E_4km book Page 16 Thursday September 7 2000 9 32 AM ...

Page 60: ...mbient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model CE 01E CE 07E EWA00012 WARNING Because loading has an enormous impact on the handling braking performance and safety characteris tics of your motorcycle you should keep the following precautions in mind NEVER OVERL...

Page 61: ...aches the specified limit if the tire has a nail or glass fragments in it or if the side wall is cracked have a Yamaha dealer replace the tire immediately CE 08E NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations EW000079 WARNING Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessiv...

Page 62: ...er 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 riding to ride conserva tively for approximately 100 km after installing a new tire ...

Page 63: ... clutch lever free play should mea sure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 If the specified clutch lever free play could be obtaine...

Page 64: ...n the adjusting nut in direction b EAU01160 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake If a brake pad has worn to the point that the...

Page 65: ...e the rubber seals may deteriorate causing leakage and poor braking perfor mance NOTE If DOT 4 is not available DOT 3 can be used for the front brake system 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 master cylinder or brake fluid reservoir when refilling Water will ...

Page 66: ...fere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU03209 Checking and lubricating the throttle grip and cable The operation of the throttle grip and the condition of the throttle cable should be checked before each ride and the cable should be lubricated or replaced if necessary NOTE Since the throttle...

Page 67: ... the brake and clutch levers 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 Throttle cable Engine oil Throttle grip housing and grip Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based gre...

Page 68: ...d down smoothly have a Yamaha dealer check or re pair it EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damag...

Page 69: ...EAU00794 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 lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Hold...

Page 70: ... which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosi...

Page 71: ...y before installation 4 After installation make sure that the battery leads are properly con nected to the battery terminals EC000102 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do ...

Page 72: ...gher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 1 Headlight fuse 2 Ignition fuse 3 Clock fuse 4 Hazard fuse 5 Main fuse 6 Spare fu...

Page 73: ...il it has cooled down 3 Place a new bulb into position and then secure it with the bulb holder EC000105 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al...

Page 74: ...the front wheel 3 Remove the brake hose holders by removing the bolts 4 Remove the brake calipers by re moving the bolts ECA00047 CAUTION Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut 5 Loosen the front wheel axle pinch bolt then the wheel axle 6 Pull the wheel axle out and then remove the wheel 1 Speedometer cable 1 Bolt 3 2 Brak...

Page 75: ...l is on the ground 5 Install the brake calipers by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 6 Tighten the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts to the specified torques 7 Connect the speedometer cable 8 Push down hard on the handlebar several times to check...

Page 76: ...he axle nut 2 Place the motorcycle on the centerstand 3 Remove the brake caliper bolts and the axle nut 4 Disconnect the brake torque rod from the brake caliper bracket by removing the cotter pin the nut and the bolt 5 While supporting the brake cali per pull the wheel axle out 6 Pull the wheel to the right to sepa rate it from the final gear case and then remove it 1 Wheel axle pinch bolt 1 Axle ...

Page 77: ...l ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 4 Install the brake torque rod bolt nut and cotter pin at the brake cal iper bracket EW000124 WARNING Always use a new cotter pin 5 Tighten the rear wheel axle pinch bolt to the specified torque 6 Take the motorcycle off the cen terstand so that the rear wheel i...

Page 78: ...e 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 inferior have a shorter service life and can lead to expensive ...

Page 79: ...ition 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 Battery The engine turns over qu...

Page 80: ...E_4km book Page 37 Thursday September 7 2000 9 32 AM ...

Page 81: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 82: ...ll 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 and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on s...

Page 83: ...d 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 84: ...ainted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor ner...

Page 85: ...ent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore...

Page 86: ...every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery s...

Page 87: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 88: ...tric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement 3 2 L With oil filter cartridge replacement 3 4 L Total amount dry engine 4 4 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti ...

Page 89: ... Transmission Primary reduction system Spur gear Primary reduction ratio 1 672 Secondary reduction system Shaft drive Secondary reduction ratio 1 278 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 188 2nd 1 500 3rd 1 154 4th 0 933 5th 0 813 Chassis Frame type Double cradle Caster angle 27 Trail 121 mm Tire Front Type Tubeless tire Size 120 70 17 58V Manufacturer model...

Page 90: ...e Cast wheel Size 17 MT 3 00 Rear Type Cast wheel Size 17 MT 4 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 gas spring oil damper Wheel travel Front 140 mm Rear 110 mm Electrical systems Ign...

Page 91: ... W 4 Meter lighting 12 V 3 4 W 4 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 2 Fuel level warning light 12 V 3 4 W 1 Fuses Main fuse 30 A Signaling system fuse 20 A Headlight fuse 15 A Hazard fuse 10 A Ignition fuse 10 A Clock fuse 10 A E_4km book Page 4 Thursday September 7 2000 9 32 AM ...

Page 92: ...tric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55 ...

Page 93: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_4km book Page 1 Thursday September 7 2000 9 32 AM ...

Page 94: ...1E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify yo...

Page 95: ...frame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_4km book Page 2 Thursday September 7 2000 9 32 AM ...

Page 96: ...uel gauge 3 5 Fuel level warning light 3 2 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3 9 Fuses replacing 6 29 H Handlebar switches 3 6 Hazard switch 3 6 Headlight bulb replacing 6 30 Helmet holder 3 11 High beam indicator light 3 3 Horn switch 3 6 I Identification numbers 9 1 Idling speed adjusting 6 15 Ignition circuit cut off system 3 15 Indicator and warning lights 3 2 K Key ident...

Page 97: ...nd lubricating 6 23 Tires 6 17 Tool kit 6 1 Troubleshooting 6 35 Troubleshooting chart 6 36 Turn signal indicator lights 3 2 Turn signal switch 3 6 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 31 Installing 6 32 Removing 6 31 Wheel rear 6 33 Installing 6 34 Removing 6 33 Wheels 6 20 E_4km book Page 2 Thursday September 7 2000 9 32 ...

Page 98: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 99: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 7 0 6 1 CR E ...

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