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PERIODIC MAINTENANCE AND MINOR REPAIR

6-22

6

EAU00635

Adjusting the throttle cable
free play

The throttle cable free play should
measure 3–5 mm (0.1–0.2 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.

EAU00637

Adjusting the valve clearance

The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.

a. Throttle cable free play

U5LV12.book Page 22 Thursday, June 27, 2002 5:49 PM

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Summary of Contents for FZ1

Page 1: ...5LV 28199 12 LIT 11626 16 33 FZS1000R FZS1000RC FZS1000SR FZS1000SRC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...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 emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these h...

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: ...PT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ U5LV12 book Page 2 Thursday June 27 2002 5 49 PM ...

Page 6: ...OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition May 2002 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 16 33 U5LV12 book Page 3 Thursday June 27 2002 5 49 PM ...

Page 7: ...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 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 8: ...INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 9: ... BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the mot...

Page 10: ... undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the op...

Page 11: ...fter operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make ...

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

Page 13: ...ol ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not...

Page 14: ...heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on yo...

Page 15: ... INFORMATION 1 2 3 4 5 6 7 8 9 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5LV12 book Page 7 Thursday June 27 2002 5 49 PM ...

Page 16: ...4 5 6 7 8 9 1 8 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 5JW 2835Y 00 1 2 3 4 5 6 7 California only U5LV12 book Page 8 Thursday June 27 2002 5 49 PM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 18: ...4 Air filter element page 6 19 5 Fuses page 6 38 6 Storage compartment page 3 12 7 Grab bar 8 Seat lock helmet holder page 3 11 9 Shock absorber assembly compression damping force adjusting screw page 3 16 10 Shock absorber assembly spring preload adjusting ring page 3 15 11 Shock absorber assembly rebound damping force adjusting knob page 3 15 12 Shift pedal page 3 7 U5LV12 book Page 1 Thursday J...

Page 19: ...r page 6 30 15 Battery page 6 37 16 Front brake fluid reservoir page 6 29 17 Radiator cap page 6 17 18 Engine oil filter cartridge page 6 13 19 Engine oil level check window page 6 12 20 Brake pedal page 3 8 21 Coolant reservoir page 6 15 U5LV12 book Page 2 Thursday June 27 2002 5 49 PM ...

Page 20: ...es page 3 6 3 Starter choke lever page 3 10 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 6 9 Brake lever page 3 7 10 Throttle grip page 6 22 U5LV12 book Page 3 Thursday June 27 2002 5 49 PM ...

Page 21: ...andlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 7 Brake pedal 3 8 Fuel tank cap 3 8 Fuel 3 9 Starter choke lever 3 10 Seat 3 11 Helmet holder 3 11 Storage compartment 3 12 Adjusting the front fork 3 12 Adjusting the shock absorber assembly 3 14 EXUP system 3 17 Sidestand 3 17 Ignition circuit cut off system 3 18 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 22: ... 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 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 ...

Page 23: ...aler check the electrical cir cuit 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 _ EAU04881 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circ...

Page 24: ... was last reset is indicated The trip meters can be used together with the fuel gauge 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 re...

Page 25: ...ck 1 Push both the SELECT and RESET buttons for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button to change the minutes 4 When the minute digits start flash ing push the RESET button to set the minutes 5 Push the SELECT button to start the clock NOTE _ After setting the clock be sure to push the SELECT button before turning t...

Page 26: ...ays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage _ EAU00110 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 L 0 9 Imp gal 1 1 US gal of fuel remain in the fuel tank If this occurs refuel as soon as possible NOTE _ Do no...

Page 27: ...turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION _ See pa...

Page 28: ...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 29: ...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 30: ...y wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts _ EAU04265 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 _ 1 Fuel tank filler tube 2 Fuel level Recommended fuel UNLEADED GASOLINE ONLY Fu...

Page 31: ...f 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 EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the ...

Page 32: ...t in place 3 Remove the key NOTE _ Make sure that the seat is properly se cured before 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...

Page 33: ... 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 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 adjust...

Page 34: ...bound damping 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 fully turned out posi...

Page 35: ...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 36: ... justment _ 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 Rebo...

Page 37: ...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 38: ...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 39: ...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 40: ...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 41: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 42: ...in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 15 6 16 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 ...

Page 43: ... 6 23 6 26 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 33 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 34 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 34 Chassis fasteners Make sure that all nuts bolts and screws are properly tightene...

Page 44: ...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 _ U5LV12 book Page 3 Thursday June 27 2002 5 49 PM ...

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 4 Engine break in 5 5 Parking 5 6 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 46: ...a tor resulting in a possible loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04827 Starting and warming up a cold engine In order for the ignition c...

Page 47: ...f the oil level warning light flick ers or remains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil 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 engine oil hav...

Page 48: ...y to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 10 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke...

Page 49: ...while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 ...

Page 50: ...re shown in the table below CF 05E EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them selves to t...

Page 51: ...ed 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 Yamahadealercheckthevehicle _ EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING _ Since the engine and exhaust system can become very hot park in a place where pedestri ...

Page 52: ...ake light switch 6 28 Checking the front and rear brake pads 6 29 Checking the brake fluid level 6 29 Changing the brake fluid 6 30 Drive chain slack 6 31 Lubricating the drive chain 6 32 Checking and lubricating the cables 6 33 Checking and lubricating the throttle grip and cable 6 33 Checking and lubricating the brake and shift pedals 6 33 Checking and lubricating the brake and clutch levers 6 3...

Page 53: ...ORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND ...

Page 54: ...a particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ U5LV12 book Page 2 Thursday June 27 2002 5 49 PM ...

Page 55: ... km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses and vacuum hose for cracks or damage Replace if necessary 5 Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for leak...

Page 56: ... damage Replace if necessary 10 Air induction system Check the air cut valve and reed valve for damage Replace the entire air induction system if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months U5LV12 book Pa...

Page 57: ... 000 km or 1 month and thereafter every 8 000 mi 13 000 km or 12 months 3 Air filter element Clean with compressed air Replace if necessary 4 Cooling system Check hose for cracks or damage Replace if necessary Replace coolant every 24 months 3 Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 7 Correct if necessary 6 Clutch Check operation Adjust or replace cable...

Page 58: ... every 16 000 mi 25 000 km or 24 months 2 Repack 14 Brake and clutch lever pivot shafts Lubricate 2 15 Brake and shift pedal pivot shafts Lubricate 2 16 Drive chain Check chain slack alignment condition Adjust and lubricate chain thoroughly 1 Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 17 Wheel bearings Check bearings for smooth operation 18 Sidestand and centerstan...

Page 59: ...mponents of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Engine oil type Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above Yamalube 4 10W 30 or engine oil SAE 10W 30 API SE for temperatures of 15 C 60 F or below _ 19 Sidestand switch Check and clean or replace if necessary...

Page 60: ...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 U5LV12 book Page 8 Thursday June 27 2002 5 49 PM ...

Page 61: ...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 U5LV12 book Page 9 Thursday June 27 2002 5 49 PM ...

Page 62: ... 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 63: ...park 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 EAU01796 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 Check each hose and canister for c...

Page 64: ...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 65: ...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 66: ...s 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 the oil level is sufficient _ 1 Torque wrench...

Page 67: ... 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 at...

Page 68: ...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 _ 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...

Page 69: ...ap EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ 5 Remove the coolant drain bolt to drain the cooling system 6 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 7 Install the coolant drain bolt and then tighten it to the specified torque NOTE _ Check the washer for damage and re place it if necessary _ 1 Radiat...

Page 70: ...diator cap start the engine let it idle for several min utes and then 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 the...

Page 71: ...nstallation procedures 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 EW000071 WARNING _ Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 4 Remove panels A and C See page 6 8 for panel removal and in stal...

Page 72: ...he air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 9 Insert the air filter element into the air filter case 1 Air filter case cover 2 Screw 4 1 Air filter element 1 Air filter element U5LV12 book Page 20 Thursday June 27 2002 5 49 PM ...

Page 73: ...ged 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 fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose in the original po sition _ 14 Install the seat EAU00628 Adjusting the carburetors The carburetors are important parts of the engine and emission contro...

Page 74: ... and if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart a Throttle cable free play U5LV12 book Page 22 Thur...

Page 75: ...acked items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if approved for th...

Page 76: ...n a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience _ Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Tire sidewall 2 Tire wear indicators a...

Page 77: ...ts 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 approximately 100 km 60 mi after install...

Page 78: ... develop its optimal characteristics EAU00691 Accessories and replacement parts EW000098 WARNING _ This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Y...

Page 79: ...rection 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 _ EAU00712 Adjusting the brake pedal position The top of the brake pedal should be po sitioned approximately 43 mm 1 7 in below the top of the footrest as shown Periodically check the brake pedal posi tion and if nec...

Page 80: ... 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 brake light switch in place To make the brake light come on earlier turn the adjusting nut in directi...

Page 81: ...ator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04856 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake 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 flu id level may indicate worn brake pads and or br...

Page 82: ...ke fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after ...

Page 83: ...f the drive chain slack is incorrect adjust it as follows EAU03608 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward a D...

Page 84: ...the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging the O rings do not clean the ...

Page 85: ... bles as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and sh...

Page 86: ...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 pair it _ Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant ...

Page 87: ...W000115 WARNING _ Securely support the motorcycle 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 Place the motorcycle on a level surface and hold it in an upright position 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 ...

Page 88: ... support the motorcycle 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 Yamaha 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 ch...

Page 89: ...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 90: ...urn 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 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 ...

Page 91: ...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 92: ... 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 93: ...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 94: ...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 95: ...heel 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 and the brake cal...

Page 96: ...n each side of the swingarm 6 Turn the drive chain slack adjust ing bolts fully in direction a 7 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE _ The drive chain does not need to be disassembled in order to remove and install the rear wheel _ 8 While supporting the wheel pull the wheel axle out 9 Remove the wheel 1 Bolt 2 2 Brake torque rod 3 Brake torque rod bo...

Page 97: ...e caliper bolts and brake torque rod nut to the specified torques EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures...

Page 98: ... 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 99: ...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 100: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 101: ...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 102: ... 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 103: ... 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 104: ...event 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 to OFF 3 Drain the carburetor float chamber by looseni...

Page 105: ... 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 Cover the muffler outlet with a plastic bag to prevent moistu...

Page 106: ...SPECIFICATIONS 8 Specifications 8 1 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 107: ...tarting 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 2 46 Imp qt 2 96 US qt With oil filter cartridge replacement 3 0 L 2 64 Imp qt 3 17 US qt Total amount dry engine 3 7 L 3 26 Imp qt 3 91 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W ...

Page 108: ...h type Wet multiple disc Transmission 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 a...

Page 109: ...Pa 2 90 kgf cm2 42 psi High speed riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi 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 ...

Page 110: ...t 12 V 5 21 W 2 Front turn signal position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 W 2 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 Radiato...

Page 111: ...identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5LV12 book Page 1 Thursday June 27 2002 5 49 PM ...

Page 112: ...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 113: ...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 U5LV12 book Page 2 Thursday June 27 2002 5 49 PM ...

Page 114: ...estigation 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 Tr...

Page 115: ...e for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 0...

Page 116: ... printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi...

Page 117: ... or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5LV12 book Page 6 Thursday June 27 2002 5 49 PM ...

Page 118: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5LV12 book Page 7 Thursday June 27 2002 5 49 PM ...

Page 119: ...CONSUMER INFORMATION 9 8 9 U5LV12 book Page 8 Thursday June 27 2002 5 49 PM ...

Page 120: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S U5LV12 book Page 9 Thursday June 27 2002 5 49 PM ...

Page 121: ...CONSUMER INFORMATION 9 10 9 U5LV12 book Page 10 Thursday June 27 2002 5 49 PM ...

Page 122: ... oil and oil filter cartridge 6 12 Engine stop switch 3 6 EXUP system 3 17 F Front fork adjusting 3 12 Front fork checking 6 35 Fuel 3 9 Fuel gauge 3 5 Fuel level warning light 3 3 Fuel tank cap 3 8 Fuses replacing 6 38 H Handlebar switches 3 6 Headlight bulb replacing 6 39 Helmet holder 3 11 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system...

Page 123: ...ter unit 3 4 Tail brake light bulb replacing 6 41 Throttle cable free play adjusting 6 22 Throttle grip and cable checking and lubricating 6 33 Tires 6 23 Tool kit 6 1 Troubleshooting 6 45 Troubleshooting charts 6 46 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 41 Turn signal switch 3 6 V Valve clearance adjusting 6 22 Vehicle identification number 9 1 W Warranty extended 9 ...

Page 124: ...PRINTED IN JAPAN 2002 06 1 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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