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PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

6

EAU22080

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the adjusting bolt 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.

EAU22240

Adjusting the brake pedal
position

The top of the brake pedal should be
positioned approximately 43.0 mm
(1.69 in) below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, have a
Yamaha dealer adjust it.

WARNING

EWA10690

A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

1. Distance between brake pedal and footrest

5LV13.book Page 24 Monday, June 9, 2003 5:08 PM

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Summary of Contents for FAZER FZS1000S

Page 1: ...5LV 28199 13 LIT 11626 17 40 FZS1000S FZS1000SC OWNER S MANUAL ...

Page 2: ...EAU10041 5LV13 book Page 1 Monday June 9 2003 5 08 PM ...

Page 3: ...s motorcycle 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 emissions 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 ...

Page 4: ...OKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED 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 RELIABILI...

Page 5: ...or Corporation U S A 1st edition June 2003 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 17 40 AFFIX DEALER LABEL HERE 5LV13 book Page 2 Monday June 9 2003 5 08 PM ...

Page 6: ...it 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 5 Removing and installing panels 6 9 Checking the spark plugs 6 10 Canister for California only 6 11 Engine oil and oil filter cartridge 6 12 Coolant 6 14 Cleaning the air filter element 6 17 Adjusting the carburetors 6 19 Adjusting the throttle cable free play 6 19 Adjusting the valve...

Page 7: ...l 6 37 Rear wheel 6 38 Troubleshooting 6 40 Troubleshooting charts 6 41 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 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 5LV13...

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

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

Page 10: ...hose provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted ...

Page 11: ...ote the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the ...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 5LV13 book Page 5 Monday June 9 2003 5 08 PM ...

Page 13: ...ION 1 6 1 1 3 4 2 5 California only 6 7 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 5JW 2835Y 00 5LV13 book Page 6 Monday June 9 2003 5 08 PM ...

Page 14: ...r filter element page 6 17 5 Fuses page 6 34 6 Storage compartment page 3 11 7 Grab bar 8 Seat lock helmet holder page 3 10 page 3 10 9 Shock absorber assembly compression damping force adjusting screw page 3 13 10 Shock absorber assembly spring preload adjusting ring page 3 13 11 Shock absorber assembly rebound damping force adjusting knob page 3 13 12 Shift pedal page 3 7 5LV13 book Page 1 Monda...

Page 15: ... reservoir page 6 26 3 Battery page 6 33 4 Front brake fluid reservoir page 6 26 5 Radiator cap page 6 14 6 Engine oil filter cartridge page 6 12 7 Engine oil level check window page 6 12 8 Brake pedal page 3 7 9 Coolant reservoir page 6 14 5LV13 book Page 2 Monday June 9 2003 5 08 PM ...

Page 16: ... switches page 3 5 3 Starter choke lever page 3 9 4 Speedometer unit page 3 3 5 Main switch steering lock page 3 1 6 Tachometer unit page 3 4 7 Fuel gauge page 3 5 8 Right handlebar switches page 3 5 9 Brake lever page 3 7 10 Throttle grip page 6 19 5LV13 book Page 3 Monday June 9 2003 5 08 PM ...

Page 17: ...680 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 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 WARNING EWA10060 Never turn the key to OFF or LOCK...

Page 18: ...on or deceleration but this is not a mal function EAU11350 Fuel level warning light This warning light comes on when the fuel level drops below approximately 4 0 L 1 06 US gal 0 88 Imp gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha d...

Page 19: ...ed together with the fuel gauge to estimate the distance that can be traveled on a full tank of fuel This in formation 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 p...

Page 20: ... clock NOTE After setting the clock be sure to push the SELECT button before turning the key to OFF otherwise the clock will not be set EAU12100 Self diagnosis devices This model is equipped with a self diag nosis device for the following electrical circuits throttle position sensor speed sensor EXUP system overturn switch If any of those circuits are defective the tachometer will repeatedly displ...

Page 21: ...2110 Fuel 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 0 L 1 06 US gal 0 88 Imp gal of fuel remain in the fuel tank If this occurs refuel as soon as possible NOTE Do not allow the fuel tank to empty itself completely EAU12341 Handlebar switches Left Right 1 Fuel gauge 1 Dimm...

Page 22: ...t this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull ...

Page 23: ... equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rea...

Page 24: ...ock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not ov...

Page 25: ... unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13590 St...

Page 26: ...o lock it in place 3 Remove the key NOTE Make sure that the seat is properly se cured before riding EAU14290 Helmet holder To open the helmet holder insert the key into the 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 WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects ca...

Page 27: ...get wet When washing the vehicle be careful not to let any water enter the storage compartment EAU14750 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 WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring ...

Page 28: ... the adjusting screw on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b 1 Current setting 2 Front fork cap bolt Spring preload setting Minimum soft 5 Standard 2 Maximum hard 1 Adjusting bolt fully turned in direction b 1 Rebound damping force adjusting screw Rebound damping s...

Page 29: ... is equipped with a spring preload adjust ing ring a rebound damping force ad justing knob and a compression damping force adjusting screw CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and there...

Page 30: ...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 WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property d...

Page 31: ...ge 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 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain...

Page 32: ... but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed...

Page 33: ...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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycl...

Page 34: ...nsequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is no...

Page 35: ...oft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 25 6 26 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reserv...

Page 36: ...ry 6 20 6 23 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 30 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tighte...

Page 37: ... pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 16 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11430 The oil level warning light coolant temperature warning light and fuel level warning light ...

Page 38: ...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 when the key is turned to ON the warning light does not come on for a few seconds then go off or if it does not go off after starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5 After starting the engine move t...

Page 39: ...0 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 transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not...

Page 40: ...U16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for t...

Page 41: ...hometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17200 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slop...

Page 42: ...EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES E...

Page 43: ...6 WARNING EWA10340 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 5LV13 book Page 2 Monday June 9 2003 5 08 PM ...

Page 44: ...k plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synchro nization Adjust synchronization of carbu retors 7 Idle speed Check and adjust engine idle...

Page 45: ...uction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 5LV13 book Page 4 Monday June 9 2003 5 08 PM ...

Page 46: ...2 Clutch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam a...

Page 47: ...epack 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Centerstand and sidestand pivots Check operation Apply lithium soap based grease all purpose grease lightly 16 ...

Page 48: ...eplace 22 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable ...

Page 49: ...unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers 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 5LV...

Page 50: ...chapter Refer to this section each time a panel needs to be removed and installed EAU19292 Panels A and C To remove one of the panels Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw 1 Panel C 2 Screw 5LV13 book Page 9 Monday June 9 2003 5 08 PM ...

Page 51: ...rk plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ 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 vehicle is ridden normally 2 Check that all spa...

Page 52: ...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 EAU19671 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Check each hose connection ...

Page 53: ... 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 change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engi...

Page 54: ...ch and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 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 tor...

Page 55: ...nd have a Yamaha dealer check the vehicle 10 Turn the engine off and then check the oil level and correct it if necessary EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU20101 To check the coolant level 1 Place the vehicle on the center stand NOTE The coola...

Page 56: ... the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator 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 41 for further instructions EAU20431 To change the coo...

Page 57: ...cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 9 Install the radiator cap start the engine let it idle for several min utes and then turn it off 10 Remove the radiator cap to check th...

Page 58: ...rvals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the seat See page 3 10 2 Remove the fuel tank bolts 3 Lift the fuel tank to position it away from the air filter case Do not dis connect the fuel hoses WARNING EWA10410 Make sure that the fuel tank is well supported Do not tilt o...

Page 59: ... filter case cover by in stalling the screws 11 Place the rubber cover in the origi nal position 12 Install the panels 13 Install the fuel tank by installing the bolts WARNING EWA11290 Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the...

Page 60: ...re all carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 1 Throttle cable free play 5LV13 book Pa...

Page 61: ...the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items tha...

Page 62: ...the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all w...

Page 63: ... high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for...

Page 64: ... to develop its optimal characteris tics EAU22010 Accessories and replacement parts WARNING EWA10620 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...

Page 65: ... a Yamaha dealer check the internal clutch mechanism EAU22240 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 43 0 mm 1 69 in below the top of the footrest as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer adjust it WARNING EWA10690 A soft or spongy feeling in the brake pedal can indicate the presence of air ...

Page 66: ...cessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22321 Checking the front and rear brake pads Front brake Rear brake 1 Rear brake light switch 2 Rear brake light switch ...

Page 67: ...ake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level mak...

Page 68: ...vals 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 intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before...

Page 69: ...g the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the lo...

Page 70: ...ry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable e...

Page 71: ...ake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating 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 Lithium soap based greas...

Page 72: ...n chart EAU23271 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 WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1...

Page 73: ...ing 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 WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Y...

Page 74: ...nd 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 explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from th...

Page 75: ...e fuses for the individual cir cuits are located under the seat See page 3 10 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 CAUTION ECA10640 Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical ...

Page 76: ...b into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of 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...

Page 77: ... brake light bulb cover 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the defective bulb by pushing it in and turning it counter clockwise 5 Insert a new bulb into 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 1 Tail brake light bu...

Page 78: ...dvisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Place the motorcycle on the 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 CAUTION EC...

Page 79: ...el 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 EAU25080 Rear wheel EAU25201 To remove the rear wheel WARNING EWA10820 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 and the brake ...

Page 80: ...to remove and install the rear wheel 8 While supporting the wheel pull the wheel axle out 9 Remove the wheel EAU25841 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 then a...

Page 81: ...on 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 properly Use only genuine Yamaha replace ...

Page 82: ... 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 83: ...the hissing 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 Chec...

Page 84: ...ve dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products o...

Page 85: ...osion 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 including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is rec...

Page 86: ...his chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent 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 ...

Page 87: ...s wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 ...

Page 88: ... L 3 17 US qt 2 64 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 2 40 L 2 54 US qt 2 11 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 21 0 L 5 55 US gal 4 62 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Carburetor Manu...

Page 89: ...8 417 lb U49 Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid Dot 4 Rear brake Type Single disc brake Op...

Page 90: ...nal light 12 V 27 0 W 2 Meter lighting 12 V 2 0 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 0 W 1 Coolant temperature indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 20 0 A Ignition fuse 20 0 A Radiator fan fuse 10 ...

Page 91: ...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 EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle a...

Page 92: ...l label is affixed to the frame under the seat See page 3 10 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 5LV13 book Page 2 Monday June 9 2003 5 08 PM ...

Page 93: ...nvestigation 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 ...

Page 94: ... hicle 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...

Page 95: ...reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 ...

Page 96: ...INFORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5LV13 book Page 6 Monday June 9 2003 5 08 PM ...

Page 97: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5LV13 book Page 7 Monday June 9 2003 5 08 PM ...

Page 98: ...CONSUMER INFORMATION 9 8 9 5LV13 book Page 8 Monday June 9 2003 5 08 PM ...

Page 99: ...ered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towi...

Page 100: ...acked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 5LV13 book Page 10 Monday June 9 2003 5 08 PM ...

Page 101: ...ap 3 8 Fuses replacing 6 34 H Handlebar switches 3 5 Headlight bulb replacing 6 35 Helmet holder 3 10 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 5 Maintenance emission co...

Page 102: ...t 6 1 Troubleshooting 6 40 Troubleshooting charts 6 41 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 37 Turn signal switch 3 6 V Valve clearance adjusting 6 20 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 33 Wheel front 6 37 Wheel rear 6 38 Wheels 6 23 5LV13 book Page 2 Monday June 9 2003 5 08 PM ...

Page 103: ...5LV13 book Page 3 Monday June 9 2003 5 08 PM ...

Page 104: ...PRINTED IN JAPAN 2003 06 0 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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