Yamaha Star XV17PCC Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

EAU22092

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 2.0–5.0 mm (0.08–0.20 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the adjusting screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).

3. Tighten the locknut.

WARNING

EWA10630

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

EAU22270

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 direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).

1. Locknut

2. Brake lever free play adjusting screw
3. Brake lever free play

1. Rear brake light switch

2. Rear brake light switch adjusting nut

U5PX16E0.book Page 23 Wednesday, May 16, 2007 10:26 AM

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Summary of Contents for Star XV17PCC

Page 1: ...5PX 28199 16 XV17PCX C XV17PCMX C OWNER S MANUAL LIT 11626 21 27 ...

Page 2: ...EAU10041 U5PX16E0 book Page 1 Wednesday May 16 2007 10 26 AM ...

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 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 h...

Page 4: ...consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET 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 The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WA...

Page 5: ...ECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without notice U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 6: ... Corporation U S A 1st edition May 2007 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 21 27 AFFIX DEALER LABEL HERE U5PX16E0 book Page 3 Wednesday May 16 2007 10 26 AM ...

Page 7: ...plugs 6 9 Canister for California only 6 10 Engine oil and oil filter cartridge 6 10 Transfer case oil 6 13 Replacing the air filter elements 6 14 Checking the engine idling speed 6 17 Checking the throttle cable free play 6 18 Valve clearance 6 18 Tires 6 18 Cast wheels 6 21 Accessories and replacement parts 6 21 Adjusting the clutch lever free play 6 22 Adjusting the brake lever free play 6 23 A...

Page 8: ...E CARE AND STORAGE 7 1 Matte color caution 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 U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 9: ...ts 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 mot...

Page 10: ...ield 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 or e...

Page 11: ...Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those 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 cleara...

Page 12: ...equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note 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 f...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5PX16E0 book Page 5 Wednesday May 16 2007 10 26 AM ...

Page 14: ...SAFETY INFORMATION 1 6 1 2 4 California only 1 3 5 California only U5PX16E0 book Page 6 Wednesday May 16 2007 10 26 AM ...

Page 15: ...0 Left view 1 Engine oil drain bolt crankcase page 6 10 2 Shift pedal page 3 6 3 Fuel tank cap page 3 7 4 Helmet holder page 3 10 5 Fuses page 6 34 6 Owner s tool kit page 6 1 U5PX16E0 book Page 1 Wednesday May 16 2007 10 26 AM ...

Page 16: ...k spring preload adjusting bolt page 3 10 6 Engine oil filter cartridge page 6 10 7 Rear brake light switch page 6 23 8 Brake pedal page 3 7 9 Engine oil drain bolt oil tank page 6 10 10 Shock absorber assembly spring preload adjusting nut page 3 11 11 Shock absorber assembly rebound damping force adjusting knob page 3 11 U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 17: ... page 3 6 2 Left handlebar switches page 3 5 3 Speedometer page 3 3 4 Tachometer unit page 3 3 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 5 7 Throttle grip page 6 18 8 Brake lever page 3 7 U5PX16E0 book Page 3 Wednesday May 16 2007 10 26 AM ...

Page 18: ...AU10660 OFF All electrical systems are off The key can be removed EAU10680 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 wh...

Page 19: ...he elec trical circuit NOTE This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit is defective the following 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 occurs have a Yamaha dealer check the vehicle EAU11480 Engine tr...

Page 20: ... electrical circuit The tachometer unit is equipped with the following an odometer which shows the to tal distance traveled 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 light came on a meter lighting control a clock a self diagnosis device NOTE Be sure to turn the key to ON b...

Page 21: ...d If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and 90 seconds have passed Meter lighting control mode 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to ON and then af ter five seconds release the SE LECT button 4 Push the RESET button to select the desired brightness...

Page 22: ...gnal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the vehicle has traveled both about 150 m 490 ft and for approximately 15 seconds However the turn signal lights can also be cancele...

Page 23: ...the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of ...

Page 24: ...072 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock co...

Page 25: ...ing fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13361 CAUTION 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 s...

Page 26: ...amaha because it can cause damage to the fuel system or ve hicle performance problems EAU34042 Rider seat To remove the rider seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the seat up and then pull the seat off To install the rider seat 1 Insert the projection on the rear of the seat into the seat holder as sh...

Page 27: ... the rider seat remove the hel met from the helmet holder and then install the seat EAU14720 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn...

Page 28: ...load 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 NOTE Use the special wrench included in the owner s tool kit to make the ad justment The spring preload setting is deter mined by measuring distance A shown in the illustration The long er distance A is the lower the s...

Page 29: ...n production the actual number of clicks always represents the entire ad justing range To obtain a precise ad justment it would be advisable to check the number of clicks of the damping force adjusting mechanism and to mod ify the specifications as necessary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following informat...

Page 30: ...e 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 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 side stand cannot be properly moved up or does not stay up otherwise the sidestand co...

Page 31: ...he 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 EWA10250 If a malfunction is noted have a...

Page 32: ...r 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 motorcycle sh...

Page 33: ...quences 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 not w...

Page 34: ...ver free play Adjust if necessary 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 23 6 24 6 25 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 reservoir If necessary ...

Page 35: ...t operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switch...

Page 36: ...is in gear with the clutch lever 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 14 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11560 The fuel level warning light and en gine trouble warning li...

Page 37: ...ON ECA10260 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 whi...

Page 38: ...cator light should come on EAU16720 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 ...

Page 39: ... cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 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 slope or on soft ground otherwise the vehicle may ov...

Page 40: ...ATED TO 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...

Page 41: ...RNING 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 U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 42: ...acks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Adjust if necessary Every 16000 mi 25000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle sp...

Page 43: ...ation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Adjust brake lever free play and 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...

Page 44: ...if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply silicone grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease all purpose grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease all purpose grease lightly 17 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly No ITE...

Page 45: ...ine oil filter car tridge Replace 24 Transfer case oil Check for leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000...

Page 46: ...fter 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 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate...

Page 47: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U5PX16E0 book Page 8 Wednesday May 16 2007 10 26 AM ...

Page 48: ... 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 49: ...nd hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the rider seat See page 3 9 3 Start the engine warm it up until the engine oil has reached a nor mal temperature of 60 C 140 F let it continue to idle for ten sec onds and then turn the engine off NOTE To achieve t...

Page 50: ...y tightened otherwise oil may seep out when the engine is run ning To change the engine oil with or without oil filter cartridge replace ment 1 Remove the rider seat See page 3 9 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the oil tank to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank 5 P...

Page 51: ...ted 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 10 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 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torques Engin...

Page 52: ...abeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 14 Install the engine oil filler cap 15 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 for the cause 16 Turn the engine off and then check the oil level and correct it if necessary 17 Install the rid...

Page 53: ...cation chart Replace the air filter elements more frequently if you are riding in un usually wet or dusty areas Air filter case element To replace the air filter element 1 Remove the rider seat See page 3 9 2 Remove the air induction system cover by removing the bolts 3 Remove the fuel tank as follows a Disconnect fuel hose A from the joint as shown b Remove the nuts c Disconnect fuel hose B from ...

Page 54: ...nect ed d Remove the hoses as shown and then remove the fuel tank by pulling it upward e Remove the foam damper 4 Remove the air filter case bolts 5 Loosen the air filter case joint clamp bolt and then pull off the air filter case 6 Remove the air filter case cover by removing the screws 7 Remove the air filter element by removing the screws 1 Hose 1 Foam damper 1 Air filter case 2 Bolt 1 Air filt...

Page 55: ...ter case cover by in stalling the screws 14 Install the air filter case by pushing it onto the air filter case joint and then tightening the clamp bolt 15 Install the air filter case by install ing the bolts 16 Install the fuel tank as follows a Install the foam damper b Place the fuel tank in the origi nal position and then connect fuel hose B and the hoses shown WARNING EWA10420 Before installin...

Page 56: ... without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 5 Install the silencer case air filter cover by installing the screws 6 Install the fuel tank See steps 16 18 under Air filter case ele ment EAU21311 Checking the engine idling speed The engine idling speed must be checked as follows and if necessary adjusted by a Yamaha dealer at the in...

Page 57: ...ecified in the periodic maintenance and lubrication chart EAU21750 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when ...

Page 58: ...ows 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 wheel and brake related parts incl...

Page 59: ...n 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 installing ...

Page 60: ...t to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamaha...

Page 61: ...tch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank case 5 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn ...

Page 62: ...f there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22270 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 ...

Page 63: ... a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU34090 Rear brake pads 1 Remove the brake caliper bolt and then tilt the caliper forward 2 Check each brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 0 8 mm 0 03 in have a Yamaha dealer ...

Page 64: ...e 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 lower the boiling point of the fluid an...

Page 65: ...enance and lubri cation chart EAU23062 To check the drive belt slack 1 Place the vehicle on the sidestand 2 Note the current position of the drive belt using the marks near the drive belt check hole NOTE The marks near the drive belt check hole are 5 0 mm 0 2 in apart 3 Note the position of the drive belt with a force of 45 N 4 5 kgf 10 lbf applied to the belt with a belt ten sion gauge as shown N...

Page 66: ...ent marks on each side of the swingarm make sure that both belt pullers are in the same posi tion for proper wheel alignment CAUTION ECA10880 Improper drive belt slack will over load the engine Keep the drive belt slack within the specified range 4 Tighten the locknuts the axle nut and the brake caliper bracket bolt to the specified torques 1 Axle nut 1 Brake caliper bracket bolt 1 Locknut 2 Drive...

Page 67: ...ce with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions 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 should be lubricated at the intervals specified in the periodic maintenance chart EAU23132 Checking and lubricating the brake and shift pedals The op...

Page 68: ...h levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricants Brake pedal Silicone grease Shift pedal Lithium soap based grease all purpose grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease all purpose grease U5PX16E0 book Page 29 Wednesday May 16 2007 10 26 AM ...

Page 69: ...it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart EAU23250 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur...

Page 70: ...o check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubricat...

Page 71: ...the wheel bearings EAU33650 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when 1 Negativ...

Page 72: ...re quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 Af...

Page 73: ...to the electrical system and possibly a fire 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Battery band 2 Battery cover 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Fuel injection system fuse 5 Backup fuse for odo...

Page 74: ...uartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Screw 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder U5PX16E0 book Page 35 Wednesday May 16 2007 10 26 AM ...

Page 75: ... the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24180 Tail brake light T...

Page 76: ... Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24321 Replacing a license plate light bulb 1 Remove the license plate light unit by removing the nuts washers and rubber dampers 2 Remove the license plate light lens by removing the nuts and washers 3 Remove the defective bulb by pull ing it out 1 Screw 1 Turn signal light bu...

Page 77: ...tion 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 using a motorcycle stand To service the ...

Page 78: ...roubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 79: ...n 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 Battery The engin...

Page 80: ... the muffler outlet 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 the drive belt and wheel axles Alwa...

Page 81: ...ter 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 corrosive in combination with water carry out the following steps after each ride i...

Page 82: ... wax spar ingly and make sure to wipe off any excess Never apply oil or wax to the drive belt Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26280 Storage Short term Always store your motorcycle in a cool dr...

Page 83: ...o ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 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 fr...

Page 84: ...rtridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Transfer gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 40 L 0 42 US qt 0 35 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel 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 Manufacturer MIKUNI Type q...

Page 85: ...90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 18M 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 DOT 4 Front suspensio...

Page 86: ...ghting 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 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A ECU Electronic Control Unit fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 7 5 A Auto decompression fuse 15 0 A U5PX16E0 book Page ...

Page 87: ...tification 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 and m...

Page 88: ...l is affixed to the frame under the rider seat See page 3 9 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 U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 89: ...nd 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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Sevent...

Page 90: ...cle 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 Ex...

Page 91: ...der 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 km or...

Page 92: ...RMATION 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 U5PX16E0 book Page 6 Wednesday May 16 2007 10 26 AM ...

Page 93: ... warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha m...

Page 94: ... later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warr...

Page 95: ... 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 towing p...

Page 96: ...ed 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 U5PX16E0 book Page 10 Wednesday May 16 2007 10 26 AM ...

Page 97: ...lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 37 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Matte color caution 7 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation 9 4 P Parking 5 4 Part locations 2 1 Pre ope...

Page 98: ...signal switch 3 5 V Valve clearance 6 18 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 32 Wheels 6 21 U5PX16E0 book Page 2 Wednesday May 16 2007 10 26 AM ...

Page 99: ...U5PX16E0 book Page 3 Wednesday May 16 2007 10 26 AM ...

Page 100: ...PRINTED IN JAPAN 2007 05 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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