Yamaha MT01S Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-6

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Hydraulic brake and clutch service

• Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
• Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master

and release cylinders, and change the brake and clutch fluids.

• Replace the brake and clutch hoses every four years and if cracked or damaged.

U5YUE5E0.book Page 6 Tuesday, March 17, 2009 9:02 AM

Summary of Contents for MT01S

Page 1: ...DIC183 MT01S OWNER S MANUAL Read this manual carefully before operating this vehicle 5YU 28199 E5 ...

Page 2: ...ion record No Contents Date To change contact person and integrate type designation 9 Jun 2005 Date of issue 1 Aug 2002 Place of issue Shizuoka Japan R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 1 2001 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC is in compliance with following norm s or documents Kind of equipment IMMOBILIZER Type designation 5SL 00 Hereby dec...

Page 3: ...n addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent p...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U5YUE5E0 book Page 1 T...

Page 5: ...NUAL 2009 by Yamaha Motor Co Ltd 1st edition March 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5YUE5E0 book Page 2 Tuesday March 17 2009 9 02 AM ...

Page 6: ...eriodic maintenance chart for the emission control system 6 2 General maintenance and lubrication chart 6 3 Removing and installing the cowling 6 7 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Air filter element 6 13 Checking the throttle cable free play 6 13 Valve clearance 6 13 Tires 6 14 Cast wheels 6 16 Clutch lever 6 16 Adjusting the rear brake light switch 6 17 Checki...

Page 7: ...ht bulb 6 31 Supporting the motorcycle 6 32 Troubleshooting 6 33 Troubleshooting chart 6 34 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U5YUE5E0 book Page 2 Tuesday March 17 2009 9 02 AM ...

Page 8: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 ...

Page 9: ...d 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 Always wear protective clothing that covers your legs ankles and feet The eng...

Page 10: ... of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any...

Page 11: ...ight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may...

Page 12: ...e 3 16 5 Shock absorber assembly compression damping force adjusting screw page 3 19 6 Shock absorber assembly spring preload adjusting nut page 3 19 7 Shift pedal page 3 11 8 Shock absorber assembly rebound damping force adjusting knob page 3 19 9 Engine oil drain bolt crankcase page 6 9 10 Engine oil drain bolt oil tank page 6 9 11 Engine oil filter cartridge page 6 9 12 Engine oil filler cap pa...

Page 13: ... reservoir page 6 18 4 Owner s tool kit page 6 1 5 Luggage strap holder page 3 21 6 Fuse box page 6 26 7 Fuel injection system fuse page 6 26 8 Main fuse page 6 26 9 Battery page 6 25 10 Headlight page 6 27 11 Brake pedal page 3 12 12 Rear brake light switch page 6 17 U5YUE5E0 book Page 2 Tuesday March 17 2009 9 02 AM ...

Page 14: ...Left handlebar switches page 3 9 3 Main switch steering lock page 3 2 4 Multi function display page 3 5 5 Front brake fluid reservoir page 6 18 6 Right handlebar switches page 3 9 7 Throttle grip page 6 13 8 Brake lever page 3 12 U5YUE5E0 book Page 3 Tuesday March 17 2009 9 02 AM ...

Page 15: ...EDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the c...

Page 16: ...s are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU36882 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the k...

Page 17: ...n 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 EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked...

Page 18: ...tection circuit the fol lowing cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times and then go off for 3 0 seconds If this oc curs have a Yamaha dealer check the vehicle EAU11534 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine If this oc curs have a...

Page 19: ...g changes to the multi function display Changing settings while riding can distract the operator and increase the risk of an accident The multi function display is equipped with the following a speedometer a tachometer an odometer two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the fuel level warning ...

Page 20: ...et the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level wa...

Page 21: ...error code TIP If the display indicates error code 52 this could be caused by transponder in terference If this error code appears try the following 1 Use the code re registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence...

Page 22: ...onds Item number 1 is displayed 4 Adjust the tachometer panel brightness level by pushing the RESET button 5 Push the SELECT button to se lect the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the RESET button 6 Push the SELECT button to se lect the tachometer needle Item number 3 is displayed Adjust the tachometer needle brightness level by pushing the RESET button 1 T...

Page 23: ...ft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information EAU12348 Handlebar switches Left 1 Tachometer needle 2 Item number 3 Brightness level 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch U5YUE5E0 book Page 9 Tuesday March 17 2009 9 02 AM ...

Page 24: ...e vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12733 Hazard switch With the key in the...

Page 25: ...ng 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 clutch lever The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 23 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutc...

Page 26: ...ip turn the adjusting knob while holding the lever pushed away from the handlebar grip When the desired position is obtained be sure to set it by aligning a groove on the adjusting knob with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 2 Brake lever position adjusting knob...

Page 27: ...g fuel is a fire hazard EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi ...

Page 28: ... on your clothing change your clothes EAU33501 NOTICE ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 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 oc curs use a gasoline ...

Page 29: ...nverters in the exhaust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any ...

Page 30: ...ont fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting bolts and compres sion damping force adjusting bolts NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload To make any adjustment of the spring preload the adjuster has to be set to the standard setting first To set the standard setting st...

Page 31: ...gnment mark on the front fork cap as shown in illustration B turn the adjusting bolt in direction b until the alignment marks match To set the standard setting turn the adjusting bolt 6 complete turns in direction b making sure the alignment marks match 1 Spring preload adjusting bolt 2 Alignment marks 2 1 b a È 1 Spring preload adjusting bolt 2 Alignment marks 1 b a 2 1 Spring preload adjusting b...

Page 32: ...k leg in direc tion b Compression damping force To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting bolt on each fork leg in direction b Spring preload setting Minimum soft 7 complete turns in direction b ...

Page 33: ...01 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in direction b Use the special wren...

Page 34: ...e and thereby harden the compres sion damping turn the adjusting screw in direction a To decrease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b 1 Special wrench 2 Extension bar 1 Distance A a b 1 2 1 Spring preload Minimum soft Distance A 165 mm 6 50 in Standard Distance A 160 mm 6 30 in Maximum hard Distance A 152 mm 5 98 in Tigh...

Page 35: ...e due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU36700 Luggage strap holders There are four luggage strap holders on the bottom of the seat To use the strap holders rem...

Page 36: ...ed on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP 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 WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the si...

Page 37: ...ission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch 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 U...

Page 38: ... 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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switc...

Page 39: ...HECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 13 Engine oil Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Front 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 reservoir If necessa...

Page 40: ...ire condition and tread depth Check air pressure Correct if necessary 6 14 6 16 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 22 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 22 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 23 Chassis fasteners Make s...

Page 41: ...idling for 30 minutes In this case the multi function display indicates error code 70 and the engine trou ble warning light comes on but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU36743 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in t...

Page 42: ...ount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with...

Page 43: ... on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17083 0 1000 km 0 600 mi Avoid prolonged operation above 2800 r min NOTICE After 1000 km 600 mi of operation the engine oil must be change...

Page 44: ...d exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U5YUE5E0 book Page 4 Tuesday March 17 2009 9 02 AM ...

Page 45: ... with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to de...

Page 46: ...require special tools data and technical skills EAU46910 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance ...

Page 47: ...on fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Check air pressure Correct if...

Page 48: ...tened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with silicone grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leak age 20 Shock absorb...

Page 49: ...oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 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 27 Lights signals and switches Check operation Adjust head...

Page 50: ...id and clutch fluid levels Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged U5YUE5E0 book Page 6 Tuesday March 17 2009 9 02 AM ...

Page 51: ... time the cowling needs to be removed and in stalled EAU36831 Cowling To remove the cowling Remove the bolts and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the bolts TIP Make sure that the grommet fits over the projection 1 Cowling 1 Cowling 2 Bolt 1 Cowling 2 Bolt 1 Cowling 2 Projection 3 Grommet U5YUE5E0 book Page 7 Tues...

Page 52: ... be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the sp...

Page 53: ...gine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature 3 Wait a few minutes until the oil set tles remove the engine oil filler cap wipe the engine oil dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level TIP The engine oil should be between the minimum and max...

Page 54: ...n oil pan under the oil tank to collect the used oil 5 Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank 6 Place an oil pan under the engine to collect the used oil 7 Remove the engine oil drain bolt to drain the oil from the crankcase TIP Skip steps 8 12 if the oil filter cartridge is not being replaced 8 Remove the rectifier regulator by removing the bolts 9 Remo...

Page 55: ... then tighten it to the specified torque with a torque wrench 12 Install the rectifier regulator by in stalling the bolts and then tighten them to the specified torque 13 Install the engine oil drain bolts and then tighten them to the spec ified torques 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening to...

Page 56: ...ls with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the oil tank 17 Install the engine oil filler cap 18 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check fo...

Page 57: ...ould 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 EAU21401 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 pe...

Page 58: ...overload your vehicle Opera tion of an overloaded vehicle could cause an accident 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 glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately TIP The tire tread depth limits may differ from country to country Always co...

Page 59: ...essure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specifie...

Page 60: ...ld be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU42850 Clutch lever Since this model is equipped with a hy draulic ...

Page 61: ...re equipped with two sets of brake pads Each front brake pad is provided with one or two wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that a wear indicator groove almost appears have a Yamaha dealer replace the brake pads as a set EAU46291 ...

Page 62: ... fluid reservoir is level Use only the recommended quality 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 lo...

Page 63: ...k The drive chain slack should be checked before each ride and adjusted if necessary EAU22773 To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of t...

Page 64: ...g 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 the drive chain as follows NOTICE ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene ...

Page 65: ...ly have a Yamaha dealer check or replace it WARNING Damage to the outer sheath may interfere with proper ca ble operation and will cause the in ner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 EAU23111 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 s...

Page 66: ...de and the pedal pivots should be lu bricated if necessary EAU43600 Checking and lubricating the brake and clutch levers Brake lever Clutch lever 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 grease U5YUE5E0 book Page 22 Tuesday March 17 2009 9 02 AM ...

Page 67: ...ndition 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 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is...

Page 68: ...ff the ground See page 6 32 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 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 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be ch...

Page 69: ...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 battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Usi...

Page 70: ...age 3 16 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 WARNING Do not use a fuse of a higher amperage rating than recommended to 1 Main fuse 2 Fuel injection system fuse 3 Fuel injection system spare fuse 4 Fuse box 1 Fuse box 2 Headlight fuse 3 Signaling s...

Page 71: ...rom 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 cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified Specified ...

Page 72: ...der c Remove the burnt out bulb d Place a new headlight bulb into position and then secure it with the bulb holder e Connect the coupler and then install the headlight bulb holder cover by turning it clockwise To replace the low beam headlight bulb a Disconnect the headlight cou pler and then remove the burnt out bulb by turning it counterclockwise 1 Do not touch the glass part of the bulb 1 Bolt ...

Page 73: ...light does not come on have a Yamaha dealer check it EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the scr...

Page 74: ...removing the screws 3 Remove the burnt out bulb by pull ing it out from the socket 4 Insert a new bulb into the socket 5 Install the license plate light lens by installing the screws 6 Install the license plate light cover by installing the screws 1 Screw 2 License plate light cover 1 Screw 2 License plate light lens 1 License plate light bulb U5YUE5E0 book Page 30 Tuesday March 17 2009 9 02 AM ...

Page 75: ... replaced 2 To replace auxiliary light bulb B or C remove the corresponding headlight unit side cover bracket and the headlight unit side cover by removing the screws 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the burnt out bulb by pull ing it out 1 Auxiliary light bulb A 2 Auxiliary light bulb B 3 Auxiliary light bulb C 1 Bolt 1 Screw 2 Headlight unit side...

Page 76: ... motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by...

Page 77: ...equire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and...

Page 78: ... vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly T...

Page 79: ...utlets with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Alway...

Page 80: ...mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corro...

Page 81: ... 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 WARNING EWA11131 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac eto...

Page 82: ...he electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the sp...

Page 83: ...artridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel injection Throttle body ID mark 5YU1 02 Spark plug s Manufacturer ...

Page 84: ...ar 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid D...

Page 85: ...ter lighting LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Parking lighting fuse 10 0 A Muffler cover fan fuse 15 0 A ECU fuse 10 0 A Fuel injection system ...

Page 86: ...ntification 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 TIP The vehicle identification number is used to identify your motorcycle and may be used to register your mo...

Page 87: ...abel is affixed to the frame under the seat See page 3 16 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 U5YUE5E0 book Page 2 Tuesday March 17 2009 9 02 AM ...

Page 88: ...ification numbers 9 1 Ignition circuit cut off system 3 23 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 4 K Key identification number 9 1 L License plate light bulb replacing 6 30 Luggage strap holders 3 21 M Main switch steering lock 3 2 Maintenance and lubrication periodic 6 3 Maintenance emission control system 6 2 Matte color caution 7 1 Model la...

Page 89: ...INDEX W Wheel bearings checking 6 24 Wheels 6 16 U5YUE5E0 book Page 2 Tuesday March 17 2009 9 02 AM ...

Page 90: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 91: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 92: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 03 0 3 1 CR E DIC183 ...

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