Yamaha TDM TWIN 900 Owner'S Manual Download Page 69 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

6

EAU00715

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake.

To check the brake pad wear, check
the position of the wear indicator while
applying the brake. If a brake pad has
worn to the point that the wear indicator
almost touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set.

1. Brake pad wear indicator groove

Front brake

1. Brake pad wear indicator groove

Rear brake

U5PSE0.book Page 24 Thursday, December 13, 2001 4:29 PM

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Summary of Contents for TDM TWIN 900

Page 1: ...5PS 28199 E0 OWNER S MANUAL TDM900 ...

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

Page 3: ... enjoy all advantages of your TDM900 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer...

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 informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM ...

Page 6: ...AL 2001 by Yamaha Motor Co Ltd 1st edition October 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5PSE0 book Page 3 Thursday December 13 2001 4 29 PM ...

Page 7: ...NT 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 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 8: ...U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however should...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 12: ...sting ring page 3 15 5 Battery page 6 33 6 Fuses page 6 34 7 Storage compartment page 3 11 8 Grab bar 9 Luggage strap holder page 3 17 10 Seat lock page 3 11 11 Shock absorber assembly rebound damping force adjusting knob page 3 15 12 Shock absorber assembly compression damping force adjusting knob page 3 16 13 Shift pedal page 3 8 14 Engine oil drain bolt A page 6 10 U5PSE0 book Page 1 Thursday D...

Page 13: ... page 6 18 18 Front brake master cylinder page 6 25 19 Radiator cap page 6 14 20 Engine oil filler cap page 6 9 21 Engine oil filter element page 6 11 22 Engine oil drain bolt B page 6 10 23 Brake pedal page 3 8 24 Rear brake fluid reservoir page 6 25 U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM ...

Page 14: ...ar switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Tachometer page 3 5 6 Coolant temperature gauge page 3 5 7 Right handlebar switches page 3 7 8 Brake lever page 3 8 9 Throttle grip page 6 18 U5PSE0 book Page 3 Thursday December 13 2001 4 29 PM ...

Page 15: ...Handlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose for Germany only 3 10 Seat 3 11 Storage compartment 3 11 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 Luggage strap holders 3 17 Sidestand 3 17 Ignition circuit cut off system 3 18 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 16: ... and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the motorcycle is moving...

Page 17: ...g when the fuel level drops be low approximately 3 5 L EAU04121 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU00061 Neutral indicator light This indicator light comes on when the transmission ...

Page 18: ...e key to ON 2 If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit 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 _ EAU04428 Speedometer unit The speedometer unit is equipped with the following a digital speed...

Page 19: ...f automatically and the display will return to TRIP 1 after refueling and traveling 5 km NOTE _ After resetting the fuel reserve tripme ter the display will return to TRIP 1 unless a different mode had been pre viously selected in that case the dis play automatically returns to the prior mode _ Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The display seg ments of the fue...

Page 20: ...tart the clock NOTE _ After setting the clock be sure to push the SELECT button before turning the key to OFF other wise the clock will not be set When the key is turned to OFF the clock display will remain on for 48 hours and then go off to pre vent the battery from discharging _ EAU01652 Coolant temperature gauge With the key in the ON position the coolant temperature gauge indicates the tempera...

Page 21: ...eturns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03826 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn ot...

Page 22: ...h to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 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...

Page 23: ...ipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear br...

Page 24: ...over 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 sure that the fuel tank cap is properly closed before riding EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not overf...

Page 25: ...ned to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs EAU00196 Fuel tank breather hose for Germany only Before operating the motorcycle Check the fuel tank breather hose connection Check the fuel tank ...

Page 26: ...ey NOTE _ Make sure that the seat is properly se cured before riding _ EAU04292 Storage compartment This storage compartment is designed to hold an optional genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage com partment securely fasten it with the straps When the U LOCK is not in the storage compartment be sure to se cure the straps to prevent losing them 1 Seat lo...

Page 27: ... 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 U5PSE0 book Page 12 Thursday December 13 2001 4 29 PM ...

Page 28: ...ad and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE _ Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt _ CI 01E 1 Spring preload adjusting bolt 2 Current setting 3 Standard setting 4 ...

Page 29: ...the damping force continue turning the adjusting screw in direction a The third click after the minimum setting is the maximum setting If the adjust ing screw is turned further in direc tion a it will move half a turn before returning to the minimum setting NOTE _ Make sure that the adjusting screw is turned to one of the four settings _ CI 01E 1 Damping force adjusting screw Minimum soft Standard...

Page 30: ...n the suspension turn the adjust ing ring in direction b CI 10E Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting knob in di rection a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in direction b CI 03E 1 Spring preload adjusting ring 2 Special wrench 3 Position indicator Sett...

Page 31: ...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 sho...

Page 32: ...n 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 sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operato...

Page 33: ...e clutch lever is not pulled It prevents 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 EW000045 WARNING _ If a malfunction is noted have a ...

Page 34: ... 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 should...

Page 35: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 36: ...eck vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 24 6 26 Rear...

Page 37: ... pivoting points if necessary 6 29 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 switches Check operation Correct if necessa...

Page 38: ...ion 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 _ U5PSE0 book Page 3 Thursday December 13 2001 4 29 PM ...

Page 39: ...RIDING POINTS 5 Starting the engine 5 1 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 40: ...rting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down _ 1 Turn the key to ON and make sure ...

Page 41: ...arting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt _ ECA00045 CAUTION _ For maximum engine life never ac celerate hard when the engine is cold _ NOTE _ The engine is warm when it quickly re sponds to the throttle _ U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM ...

Page 42: ...cle 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 dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02937 Recommended shift points for Switzerland only The recommended shift points d...

Page 43: ...ad the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU04315 0 1 000 km Avoid prolonged operation above ...

Page 44: ...he key from the main switch EW000058 WARNING 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 motorcycle may overturn U5PSE0 book Page 5 Thursday December 13 2001 4 29 PM ...

Page 45: ... level 6 25 Changing the brake fluid 6 26 Drive chain slack 6 26 Lubricating the drive chain 6 28 Checking and lubricating the cables 6 28 Checking and lubricating the throttle grip and cable 6 29 Checking and lubricating the brake and shift pedals 6 29 Checking and lubricating the brake and clutch levers 6 29 Checking and lubricating the sidestand 6 30 Lubricating the rear suspension 6 30 Checkin...

Page 46: ...ycle maintenance work have a Yamaha dealer do it for you EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 11 for seat removal procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever add...

Page 47: ...ECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40 000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 7 Rear brake Check opera...

Page 48: ...Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based g...

Page 49: ... rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Air induction system Check the air cut off valve read valve and hose for damage Replace the entire air induction system if necessary 28 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 29 Muffler and exhaust pipe Ch...

Page 50: ...lled EAU04039 Cowling A and B To remove one of the cowlings Remove the screws and the quick fas tener and then pull the cowling off as shown NOTE _ The quick fastener is removed by push ing the center pin in with a screwdriver then pulling the fastener out _ To install the cowling Place the cowling in the original posi tion and then install the screws and the quick fastener 1 Cowling A 2 Panel A 1...

Page 51: ...317 Panels A and B To remove one of the panels 1 Remove the corresponding cowl ing A or B See page 6 5 for cowl ing removal and installation procedures 2 Remove the seat See page 3 11 for seat removal and installation procedures 3 Remove the screw and then take the panel off To install the panel 1 Place the panel in the original po sition and then install the screw 2 Install the seat and the cowli...

Page 52: ...l spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 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...

Page 53: ...rench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ U5PSE0 book Page 8 Thursday December 13 2001 4 29 PM ...

Page 54: ...f 3 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and with the arrow mark pointing upward as shown and then remove it again to check the oil level NOTE _ The engine oil should be between the minimum and maximum level marks _ EC000000 CAUTION _ Do not operate the motorcycle until you know th...

Page 55: ...engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolts to drain the oil from the crankcase NOTE _ Skip steps 4 6 if the oil filter element is not being replaced _ 4 Remove the oil filter element cover by removing t...

Page 56: ...ls of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off and then check the oil level and correct it if necessa...

Page 57: ...torcycle 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 or below the minimum level mark remove panel B See page 6 6 for panel removal and installation proce dures remove the reservoi...

Page 58: ...7 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 44 for further instructions _ EAU04461 To change the coolant 1 Place the motorcycle on a level surface and let the engine cool if necessary 2 Remove the seat See page 3 11 ...

Page 59: ...eservoir upward and away from the motorcycle 10 Drain the remaining coolant from the coolant reservoir by opening the cap then turning the reservoir upside down 11 Install the coolant reservoir by placing it in the original position and then installing the bolt 12 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 1 Radiator cap retaining bolt 2 Radia...

Page 60: ...ze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 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 and the cap ...

Page 61: ...k the cooling system EAU04431 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Remove cowlings A and B as well as panels A a...

Page 62: ...the bolts EWA00013 WARNING _ Make sure that the fuel hose and breather hose are properly connect ed and routed and not pinched Re place any damaged hoses _ 9 Install the panels and cowlings 10 Install the seat EAU00632 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication...

Page 63: ...hrottle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary 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 ...

Page 64: ...recautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider pas senger cargo and accessories does not exceed the specified maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the cen...

Page 65: ...a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control 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 wi...

Page 66: ...er 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 after installing a new tire ...

Page 67: ... To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 Tighten the locknut NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism 1 Locknut 2 Clutch lever free play adjusting bol...

Page 68: ...ulic system will diminish the braking performance which may result in loss of control and an accident EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear ...

Page 69: ...ator which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set 1 Brake pad wear indicator groove Front brake 1 Brake pad wear indicator...

Page 70: ...ake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lo...

Page 71: ... The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright position NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight on it 2 Shift the transmission into the neu tral position 3 Move the rear w...

Page 72: ...that both chain pullers are in the same posi tion for proper wheel alignment _ EC000096 CAUTION _ Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits _ 3 Tighten the locknuts and then tighten the axle nut and the brake cali...

Page 73: ... Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and t...

Page 74: ... and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease a...

Page 75: ...000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU04282 Lubricating the rear suspension 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 purpose grease Recommended lubricant Lithium soap based grea...

Page 76: ...n 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be che...

Page 77: ...a dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5PSE0 book Page 32 Thursday December 13 2001 4 29 PM ...

Page 78: ... 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 batte...

Page 79: ...rn 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 _ 1 Backup fuse odometer and clock 2 Radiator fan fuse 3 Turn signal and hazard light fuse 4 I...

Page 80: ...lb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 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 _ 3 Place a new headlight bulb into position and then secure it ...

Page 81: ...onnect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU04411 Replacing a tail brake light bulb 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in...

Page 82: ... a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a moto...

Page 83: ... that there is no danger of it falling over _ 1 Loosen the front wheel axle pinch bolt then the brake caliper bolts 2 Loosen the wheel axle with a19 mm hexagon wrench 3 Lift the front wheel off the ground according to the procedure on page 6 37 4 Remove the brake hose holders by removing the bolts 5 Remove the brake calipers by re moving the bolts 6 Pull the wheel axle out and then remove the whee...

Page 84: ...stalling the bolts 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU04455 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 ...

Page 85: ...f the swingarm 6 Turn the drive chain slack adjust ing bolts fully in direction a 7 Push the wheel forward tighten the caliper bracket bolt 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 _ 1 Quick fastener 2 Pin After removal Before installation 1 Axle nut 2 Drive chain slack adjusting bol...

Page 86: ...oosen the brake caliper bracket bolt 4 Adjust the drive chain slack See page 6 27 for drive chain slack ad justment procedures 5 Install the axle nut and then lower the rear wheel so that it is on the ground 6 Tighten the axle nut and the brake caliper bracket bolt to the specified torques 7 Install the drive chain cover by in stalling the bolts and quick fasten ers NOTE _ To install a quick faste...

Page 87: ...troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 88: ... 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 89: ...ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ CT 2AE 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 Che...

Page 90: ...U5PSE0 book Page 45 Thursday December 13 2001 4 29 PM ...

Page 91: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 92: ...rical 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 e...

Page 93: ...astic may leave scratches on the wind shield 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...

Page 94: ...e thermally in duced discoloring of stainless steel exhaust 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 mo...

Page 95: ...00014 CAUTION _ Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored _ Long term Before storing your motorcycle for several months 1 Follow all the instructions in the...

Page 96: ...urning the engine over _ 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand 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 from becoming degraded in one spot 6 Cover ...

Page 97: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 98: ...stem Electric starter Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 3 8 L With oil filter element replacement 3 9 L Total amount dry engine 4 7 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti ...

Page 99: ...ion system Chain drive Secondary reduction ratio 2 625 Number of drive chain sprocket teeth front rear 16 42 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 750 2nd 1 947 3rd 1 545 4th 1 240 5th 1 040 6th 0 923 Chassis Frame type Diamond Caster angle 25 5 Trail 114 mm Tires Front Type Tubeless tire Size 120 70 ZR18 59W 120 70 ZR18 M C 59W Manufacturer model Dunlop D220...

Page 100: ... 50 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 18 MT 3 50 18 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 00 17 M C MT 5 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm monocross Spring shock absorber Front Coil spring o...

Page 101: ...ignal light 12 V 10 W 4 Meter lighting 12 V 2 W 2 Neutral indicator light 14 V 1 2 W 1 High beam indicator light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 2 W 2 Oil level warning light L E D Engine trouble warning light 14 V 1 4 W 1 Fuses Main fuse 40 A Headlight fuse 15 A Signaling system fuse 7 5 A Ignition fuse 10 A Parking lighting fuse 5 A Turn signal and hazard light fuse 10 A Backup f...

Page 102: ...PERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg...

Page 103: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM ...

Page 104: ...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 yo...

Page 105: ...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 U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM ...

Page 106: ...ng light 3 3 F Front fork adjusting 3 13 Front fork checking 6 31 Fuel 3 9 Fuel consumption tips for reducing 5 4 Fuel level warning symbol 3 2 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3 9 Fuses replacing 6 34 H Handlebar switches 3 6 Hazard switch 3 6 Headlight bulb replacing 6 35 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Idling speed adjusting 6 17...

Page 107: ...Throttle cable free play adjusting 6 18 Throttle grip and cable checking and lubricating 6 29 Tires 6 19 Tool kit 6 1 Troubleshooting 6 42 Troubleshooting charts 6 43 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 37 Turn signal switch 3 6 V Valve clearance adjusting 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheel front 6 38 Installing 6 39 Removing...

Page 108: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 109: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 110: ...PRINTED IN JAPAN 2001 11 1 0 3 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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