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PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

6

EAU04005

Adjusting the clutch lever free
play

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

a

.

To decrease the clutch lever free play,
turn the adjusting bolt in direction

b

.

NOTE:

_

If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.

_

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

U5LVE2.book Page 24 Thursday, June 27, 2002 5:23 PM

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Summary of Contents for Fazer 1000-EXUP

Page 1: ...5LV 28199 E2 FZS1000 FZS1000S OWNER S MANUAL ...

Page 2: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 3: ...s to enjoy all advantages of your FZS1000 FZS1000S 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 ...

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 informa...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING _ PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE _ U5LVE2 book Page 2 Thursday June 27 2002 5 23 PM ...

Page 6: ...ER S MANUAL 2002 by Yamaha Motor Co Ltd 1st edition May 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5LVE2 book Page 3 Thursday June 27 2002 5 23 PM ...

Page 7: ...MENT 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 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 8: ...U5LVE2 book Page 2 Thursday June 27 2002 5 23 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 10: ...f 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 shou...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 12: ... filter element page 6 15 5 Fuses page 6 36 6 Storage compartment page 3 13 7 Grab bar 8 Seat lock helmet holder page 3 11 page 3 12 9 Shock absorber assembly compression damping force adjusting screw page 3 17 10 Shock absorber assembly spring preload adjusting ring page 3 16 11 Shock absorber assembly rebound damping force adjusting knob page 3 16 12 Shift pedal page 3 8 U5LVE2 book Page 1 Thurs...

Page 13: ...ir page 6 27 15 Battery page 6 35 16 Front brake fluid reservoir page 6 27 17 Radiator cap page 6 14 18 Engine oil filter cartridge page 6 10 19 Engine oil level check window page 6 9 20 Brake pedal page 3 9 21 Coolant reservoir page 6 12 U5LVE2 book Page 2 Thursday June 27 2002 5 23 PM ...

Page 14: ...es page 3 7 3 Starter choke lever page 3 11 4 Speedometer unit page 3 4 5 Main switch steering lock page 3 1 6 Tachometer unit page 3 5 7 Fuel gauge page 3 6 8 Right handlebar switches page 3 7 9 Brake lever page 3 8 10 Throttle grip page 6 19 U5LVE2 book Page 3 Thursday June 27 2002 5 23 PM ...

Page 15: ...andlebar switches 3 7 Clutch lever 3 8 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 9 Fuel tank cap 3 9 Fuel 3 10 Fuel tank breather hose 3 11 Starter choke lever 3 11 Seat 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 EXUP system 3 18 Sidestand 3 18 Ignition circuit cut off system 3 19 U5LVE2 book Page 1 Thursday June 27...

Page 16: ...OTE _ 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 removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF...

Page 17: ...e off The key can be removed The steering must be locked before the key can be turned to ECA00043 CAUTION _ Do not use the parking position for an extended length of time other wise the battery may discharge _ EAU03034 Indicator and warning lights EAU04121 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right 1 Push 2...

Page 18: ... 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 by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit EC000002 CAUTION _ Do not operate the engine if it is overheated _ EAU04878 Fuel level ...

Page 19: ...e to estimate the distance that can be traveled on a full tank of fuel This information will enable you to plan future fuel stops To set a mode Push the SELECT button to change between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO To reset a meter To reset either tripmeter 1 or 2 to 0 0 select either by pushing the SELECT button and th...

Page 20: ... After setting the clock be sure to push the SELECT button before turning the key to OFF otherwise the clock will not be set _ EAU04290 Self diagnosis devices This model is equipped with a self di agnosis device for the following electri cal circuits throttle position sensor speed sensor EXUP system overturn switch If any of those circuits are defective the tachometer will repeatedly display the f...

Page 21: ...uel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E approximately 4 L of fuel remain in the fuel tank If this occurs refuel as soon as possible NOTE _ Do not allow the fuel tank to empty it self completely _ EAU00109 Anti theft alarm optional This motorcycle can be equipped with an optional an...

Page 22: ...t simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when your motorcycle is stopped where it might be a traffic hazard EC000006 CAUTION _ Do not use the hazard light for an ex tended length of time otherwise the battery may discharge _ EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to...

Page 23: ...tion with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handlebar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn ...

Page 24: ...nk cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE _ The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNING _ Make...

Page 25: ...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 exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded ...

Page 26: ...Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU03956 Seat To remove the seat 1 Insert the key into the seat lock and then turn it clockwise 2 While holding the key in that posi tion lift the rear of the seat and then pull the se...

Page 27: ...e riding _ EAU04291 Helmet holder To open the helmet holder insert the key into the seat lock and then turn the key as shown To lock the helmet holder turn the key to the original position and then re move it EW000030 WARNING _ Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident _ 1 Projection 2 Seat holder 1 Helm...

Page 28: ...nts in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the motorcycle be careful not to let any water enter the storage compartment EAU04293 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting screws EW000035 WARNING _ Alway...

Page 29: ...ping force and thereby harden the rebound damping turn the adjusting screw on each fork leg in direction a To de crease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in direction b CI 02E 1 Spring preload adjusting bolt 1 Current setting 2 Front fork cap bolt Setting Minimum soft 5 Standard 2 Maximum hard 1 Adjusting bolt fully turned in...

Page 30: ...uction 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 _ EAU04295 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping f...

Page 31: ...stment _ CI 10E Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting knob in di rection a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in direction b CI 03E 1 Spring preload adjusting ring 2 Special wrench 3 Position indicator Setting Minimum soft 1 Standard 6 Maximum hard 11 1 ...

Page 32: ...ns as necessary _ EAU00315 WARNING _ This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under 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 s...

Page 33: ...e of the frame Raise the sidestand or lower it with your foot while holding the motorcycle upright NOTE _ The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system _ EW000044 WARNING _ The motorcycle must not be ridden with the sidestand down or if the sidesta...

Page 34: ...events starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000046 WARNING _ The vehicle must be placed on the centerstand during this in specti...

Page 35: ...he 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 shou...

Page 36: ...U5LVE2 book Page 21 Thursday June 27 2002 5 23 PM ...

Page 37: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 38: ...n engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to sp...

Page 39: ... 6 20 6 23 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 31 6 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tig...

Page 40: ...ction can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle _ U5LVE2 book Page 3 Thursday June 27 2002 5 23 PM ...

Page 41: ... 5 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 5 Parking 5 5 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 42: ...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 20 Never ride with the sidestand down _ 1 Turn the key to ON and make sure that the engine stop switch...

Page 43: ...ngine and then check the coolant level and the vehicle for coolant leakage If necessary add coolant and then check the warning light again If when the key is turned to ON the warn ing light does not come on for a few seconds then go off or if it does not go off after starting with sufficient coolant have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on afte...

Page 44: ...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 tra...

Page 45: ...tion depends largely on your riding style Consider the following tips to reduce fuel consumption Turn the starter choke off as soon as possible Shift up swiftly and avoid high en gine speeds during acceleration Do not rev the engine while 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 traf...

Page 46: ...0 r min 1 000 1 600 km Avoid prolonged operation above 6 000 r min EC000052 CAUTION _ After 1 000 km of operation the en gine oil must be changed and the oil filter cartridge replaced _ 1 600 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...

Page 47: ... 26 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Drive chain slack 6 28 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and cable 6 30 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and clutch levers 6 31 Checking and lubricating the centerstand and sidestand 6 31 ...

Page 48: ...le maintenance work have a Yamaha dealer do it for you _ EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 11 for seat removal procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever add...

Page 49: ...0 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 40 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 8 Re...

Page 50: ...ners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based gr...

Page 51: ...nd rear brake switches Check operation 27 Moving parts and cables Lubricate 28 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 29 Air induction system Check the air cut off valve read valve and hose for damage Replace the entire air induction system if necessary 30 Muffler and exhaust pipe ...

Page 52: ...rm some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU04003 Panels A and C To remove one of the panels Remove the screw and then pull the panel off as shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw U5LVE2 book Page 5 Thursday June 27 2002 5 23 PM ...

Page 53: ...l position and then install the screw EAU01315 Panel B To remove the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 1 Panel C 2 Screw 1 Panel B 2 Screw 3 U5LVE2 book Page 6 Thursday June 27 2002 5 23 PM ...

Page 54: ... ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to ...

Page 55: ... 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque 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 _ 4 Install the spark plug cap a Spark plug gap Spark plug gap 0 7 0 8...

Page 56: ...p for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To...

Page 57: ...imilar device to keep the oil away from the exhaust pipe _ 4 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 5 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 _ 1 Engine oil drain bolt Left Side 1 Oil filter wrench 2 Oil filter cartridge 1 O rin...

Page 58: ...y than specified 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 warning light should go off if th...

Page 59: ...d NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should be between the minimum and maximum level marks _ 3 If the coolant is a...

Page 60: ...as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 45 for further instructions _ EAU04299 To change the coolant 1 Place the motorcycle ...

Page 61: ...in bolt and then tighten it to the specified torque NOTE _ Check the washer for damage and re place it if necessary _ 8 Pour the recommended coolant into the radiator until it is full 1 Radiator cap 1 Coolant drain bolt Tightening torque Coolant drain bolt 7 Nm 0 7 m kgf Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhib itors for aluminum engines Antifreeze...

Page 62: ...hen turn it off 10 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 11 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 12 Start the engine and then check the vehicle f...

Page 63: ...orted Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 4 Remove panels A and C See page 6 5 for panel removal and in stallation procedures 5 Pull the rubber cover off its hold ers 6 Remove the air filter case cover by removing the screws 1 Bolt 3 1 Rubber cover 2 Rubber cover holder 2 1 Air filter case cover 2 Screw 4 U5LVE2 book P...

Page 64: ... filter element into the air filter case ECA00089 CAUTION _ The engine should never be operat ed without the air filter element in stalled otherwise the pistons and or cylinders may become excessively worn _ 10 Install the air filter case cover by installing the screws 11 Place the rubber cover in the orig inal position 12 Install the panels 13 Install the fuel tank by installing the bolts 1 Air f...

Page 65: ...The carburetors are important parts of the engine and require very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment described in the following section however may be serviced by the owner as part of routine maintenance EC000095 CAUTION _ The carburetors have been set and e...

Page 66: ...on by turning the throttle stop screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b NOTE _ If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment _ EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm at the throt...

Page 67: ...y adjusted before each ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient 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 Tire air pressure measured on cold t...

Page 68: ... during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride _ Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or...

Page 69: ...ycle is equipped with cast wheels and tubeless tires with valves EW000080 WARNING _ The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely installed to pr...

Page 70: ...y 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...

Page 71: ...ncrease the clutch lever free play turn the adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE _ If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism _ 1 Clutch lever free play adjusting bolt c Clutch lever free play U5LVE2 ...

Page 72: ...c system will diminish the braking performance which may result in loss of control and an accident _ EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear b...

Page 73: ...ed with a wear indicator groove which allows you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set 1 Brake pad wear indicator groove Front 1 Brake pad wear indicator groove Re...

Page 74: ...y 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 and may result in vapo...

Page 75: ...lace every two years Brake hoses Replace every four years EAU00745 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive ...

Page 76: ... from occurring keep the drive chain slack within the specified limits _ 3 Tighten the locknuts and then tighten the axle nut to the specified torque EAU03006 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 ...

Page 77: ...able ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 WARNING _ 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 _ EAU04034 Checking and lubricating the throttle grip and cable T...

Page 78: ...lever pivots should be lu bricated if necessary EAU03371 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EW000114 WARNING _ If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re p...

Page 79: ...ting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease U5LVE2 book Page 32 Thursday June 27 2002 5 23 PM ...

Page 80: ...n 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...

Page 81: ...aha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5LVE2 book Page 34 Thursday June 27 2002 5 23 PM ...

Page 82: ...ompt 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 ALL BATTER IES OUT OF THE REACH OF CHILDREN _ 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...

Page 83: ...ectrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher 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 blo...

Page 84: ...d then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ 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 position and then secure it with the bulb holder 1 Headlight bulb cover 2 Headlight coupler 1 Headli...

Page 85: ... 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 _ 5 Install the headlight bulb cover and then connect the coupler 6 Install the panel 7 Have a Yamaha deal...

Page 86: ...the socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the bulb cover 8 Install the seat EAU03497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it...

Page 87: ...e cen terstand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 3 Remove the brake hose holder on each side by removing the bolts 4 Remove the brake caliper on each side by removing the bolts ECA00046 CAUTION _ Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut _ 5 Pull the wheel axle out and then r...

Page 88: ...heel axle the wheel axle pinch bolt and the brake cali per bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU03964 Rear wheel To remove the rear wheel EW000122 WARNING _ It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over _ 1 Loosen the axle nut an...

Page 89: ...er to remove and install the rear wheel _ 8 While supporting the wheel pull the wheel axle out 9 Remove the wheel EAU03895 To install the rear wheel 1 Place the wheel and the brake cal iper bracket in the original position 2 Insert the wheel axle through the brake caliper bracket and wheel from the right hand side and then install the axle nut 3 Install the drive chain onto the rear sprocket and t...

Page 90: ...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 experience and know how to service the motorcycle ...

Page 91: ... 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 Batter...

Page 92: ...iss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ NOTE _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Ch...

Page 93: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 94: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners...

Page 95: ... Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind 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 i...

Page 96: ... systems can be re moved through polishing 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 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 EWA00...

Page 97: ...w 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 Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever t...

Page 98: ...e turning the engine over _ 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cov...

Page 99: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 100: ...system 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 8 L With oil filter cartridge replacement 3 0 L Total amount dry engine 3 7 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 In order to prevent clutch slippage since the...

Page 101: ... Primary reduction system Spur gear Primary reduction ratio 1 581 Secondary reduction system Chain drive Secondary reduction ratio 2 750 Number of drive chain sprocket teeth front rear 16 44 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 Double cradle Caster angle 26 Trail 104 mm Tires Front Type...

Page 102: ...2 50 kgf cm2 2 50 bar Rear 290 kPa 2 90 kgf cm2 2 90 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 50 17 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 50 17 M C MT 5 50 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 li...

Page 103: ... 5 21 W 2 Turn signal light 12 V 21 W 4 Meter lighting 12 V 2 W 3 Neutral indicator light 14 V 1 4 W 1 High beam indicator light 14 V 1 4 W 1 Oil level warning light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 4 W 2 Fuel level warning light 12 V 2 W 1 Coolant temperature warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Radiator fan fuse 10 A Ignition fuse 20 A Signaling system fuse 2...

Page 104: ...PERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lbf in lbf ft lbf in lbf 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 Miscellaneou...

Page 105: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 U5LVE2 book Page 1 Thursday June 27 2002 5 23 PM ...

Page 106: ...E 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 ...

Page 107: ...e 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 U5LVE2 book Page 2 Thursday June 27 2002 5 23 PM ...

Page 108: ...dling speed 6 19 Engine oil and oil filter cartridge 6 9 Engine stop switch 3 7 EXUP system 3 18 F Front fork adjusting 3 13 Front fork checking 6 33 Fuel 3 10 Fuel consumption tips for reducing 5 4 Fuel gauge 3 6 Fuel level warning light 3 3 Fuel tank breather hose 3 11 Fuel tank cap 3 9 Fuses replacing 6 36 H Handlebar switches 3 7 Hazard switch 3 7 Headlight bulb replacing 6 37 Helmet holder 3 ...

Page 109: ...r unit 3 5 Tail brake light bulb replacing 6 39 Throttle cable free play adjusting 6 19 Throttle grip and cable checking and lubricating 6 30 Tires 6 20 Tool kit 6 1 Troubleshooting 6 43 Troubleshooting charts 6 44 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 39 Turn signal switch 3 7 V Valve clearance adjusting 6 20 Vehicle identification number 9 1 W Wheel bearings checkin...

Page 110: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 111: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 112: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2002 06 0 3 1 CR E ...

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