Yamaha Thunderace YZF1000R Owner'S Manual Download Page 60 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-15

6

7. Lightly tap the air filter element to

remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.

8. Insert the air filter element into the

air filter case.

EC000082*

CAUTION:

_

●

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

●

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.

_

9. Install the air filter case cover by

installing the screw.

10. Install the fuel tank by installing the

bolts.

EW000072

WARNING

_

●

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.

●

Make sure that the fuel hoses
are properly connected and
routed, and not pinched.

_

11. Install the cowlings, and then in-

stall the rider seat.

E_4sv.book Page 15 Friday, November 10, 2000 3:03 PM

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Summary of Contents for Thunderace YZF1000R

Page 1: ...4SV 28199 E4 OWNER S MANUAL YZF1000R ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ...to enjoy all advantages of your YZF1000R 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 de...

Page 4: ...e 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 informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING _ PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE _ E_4sv book Page 2 Friday November 10 2000 3 03 PM ...

Page 6: ...NUAL 2000 by Yamaha Motor Co Ltd 1st Edition September 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4sv book Page 3 Friday November 10 2000 3 03 PM ...

Page 7: ...ENT 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 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 8: ...E_4sv book Page 2 Friday November 10 2000 3 03 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_4sv book Page 1 Friday November 10 2000 3 03 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 shoul...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 12: ...r page 3 12 5 Rider seat lock page 3 11 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 8 Shock absorber assembly compression damping force adjusting screw page 3 16 9 Main fuse page 6 32 10 Shift pedal page 3 7 11 Front fork compression damping force adjusting screw page 3 14 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 13: ...e 3 15 17 Fuel tank page 3 9 18 Front fork spring preload adjusting bolt page 3 13 19 Front fork rebound damping force adjusting screw page 3 14 20 Headlight page 6 33 21 Engine oil filter cartridge page 6 9 22 Brake pedal page 3 8 23 Shock absorber assembly rebound damping force adjusting knob page 3 16 24 Rear brake fluid level check window page 6 23 E_4sv book Page 2 Friday November 10 2000 3 0...

Page 14: ...ebar switches page 3 5 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Tachometer page 3 4 6 Coolant temperature gauge page 3 5 7 Right handlebar switches page 3 6 8 Throttle grip page 6 17 9 Brake lever page 3 8 E_4sv book Page 3 Friday November 10 2000 3 03 PM ...

Page 15: ...switches 3 5 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose 3 10 Starter choke lever 3 10 Seats 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 Luggage strap holders 3 17 EXUP system 3 17 Sidestand 3 18 Ignition circuit cut off system 3 18 E_4sv book Page 1...

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 movi...

Page 17: ...mes on when the engine oil level is low The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push the start switch If the warn ing light does not come on while pushing the start switch have a Yamaha dealer check the electr...

Page 18: ... Turn signal indicator light This indicator light flashes 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 EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the tot...

Page 19: ...the following error code CB 11E Use the chart below to identify the faulty electrical circuit CB 22E If the tachometer displays such an er ror code note the circuit specific num ber of r min and then have a Yamaha dealer check the motorcycle EC000004 CAUTION _ When the tachometer displays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage _ 1 Tachome...

Page 20: ...02 CAUTION _ Do not operate the engine if it is overheated _ EAU00109 Anti theft alarm optional This motorcycle can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information EAU00118 Handlebar switches EAU00120 Pass switch PASS Press this switch to flash the headlight EAU03888 Dimmer switch Set this switch to for the high beam and to for the low ...

Page 21: ...fore starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU03898 Light switch Set this switch to to turn on the auxiliary light meter lighting and tail light Set the switch to to turn on the headlight also Set this switch to to turn off all the lights EAU00143 Start switch Push this switch to...

Page 22: ...m 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 ignition circuit cut off system See page 3 18 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used i...

Page 23: ... 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 brake press down on the brake pedal 1 Brake lever position adjusting dial 2 Brake lever 3 Arrow mark a Di...

Page 24: ...er 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...

Page 25: ...ank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the l...

Page 26: ...f the seat down to lock it in place 2 Remove the key Passenger seat To remove the passenger seat 1 Remove the rider seat 2 Pull the passenger seat up To install the passenger seat 1 Insert the projection on the rear of the passenger seat and the hooks on the front of the passenger seat into the seat holders as shown and then push the seat toward the back 2 Install the rider seat 1 Rider seat lock ...

Page 27: ...t removal and installation procedures 2 Attach the helmet to the helmet holder and then securely install the seat EW000030 WARNING _ Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident _ To release the helmet from the hel met holder Remove the rider seat remove the hel met from the helmet holder and then install t...

Page 28: ...ompartment EAU01862 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting screws EW000035 WARNING _ Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result _ Spring preload To increase the spring preload and thereby harden the suspension turn th...

Page 29: ...rection a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b CI 02E 1 Current setting 2 Front fork cap bolt Setting Minimum soft 5 Standard 4 Maximum hard 1 1 Rebound damping force adjusting screw Minimum soft 17 clicks in direction b Standard 9 clicks in direction b Maximum hard 0 clicks in direction b Wit...

Page 30: ...specifications as necessary _ EAU01699 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping force ad justing knob and a compression damping force adjusting screw EC000015 CAUTION _ Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings _ Spring preload To increase the spring preload and t...

Page 31: ... of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary _ 1 Rebound damping force a...

Page 32: ... dealer service the shock absorber _ EAU00324 Luggage strap holders There are four luggage strap holders below the passenger seat two of which can be turned out for easier access EAU01571 EXUP system This motorcycle is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe The EXUP system v...

Page 33: ...filling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly _ EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when t...

Page 34: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 35: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 36: ...cessary 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 21 6 24 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic sy...

Page 37: ...res Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6...

Page 38: ...E_4sv book Page 3 Friday November 10 2000 3 03 PM ...

Page 39: ...S 5 Starting the engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 40: ...e starting 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 ...

Page 41: ...rning light does not come on when push ing the start switch or if it does not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on...

Page 42: ...n press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it _ EC000048 CAUTION _ 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 tra...

Page 43: ...while shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU00436 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 000 km For this rea son you should read the following ma ...

Page 44: ...UTION _ After 1 000 km of operation the en gine oil must be changed and the oil filter cartridge replaced _ 1 000 km and beyond The vehicle can now be operated nor mally EC000053 CAUTION _ Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle _ EAU00460 Parking When parking stop...

Page 45: ...ng the brake fluid level 6 22 Changing the brake fluid 6 24 Drive chain slack 6 25 Lubricating the drive chain 6 26 Checking and lubricating the cables 6 27 Checking and lubricating the brake and shift pedals 6 27 Checking and lubricating the brake and clutch levers 6 27 Checking and lubricating the sidestand 6 28 Lubricating the rear suspension 6 28 Checking the front fork 6 29 Checking the steer...

Page 46: ...otor cycle maintenance work have a Yamaha dealer do it for you _ EAU03713 Owner s tool kit The tool kit is located under the pas senger seat See page 3 11 for pas senger 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 additional t...

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

Page 48: ...r riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check operati...

Page 49: ...ner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged _ 23 Engine oil Change 24 Engine oil filter cartridge Replace 25 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving...

Page 50: ...the cowling Remove the cowling screws and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screws EAU03946 Cowling B To remove the cowling 1 Remove the rider and passenger seats See page 3 11 for rider and passenger seat removal and installation procedures 2 Remove the cowling screws and then pull the cowling off as shown 1 ...

Page 51: ...move the cowling 1 Remove the cowling bolts 2 Disconnect the turn signal light lead connectors and then take the cowling off To install the cowling 1 Connect the turn signal light lead connectors 2 Place the cowling in the original position 3 Install the cowling bolts 1 Bolt 14 Left side Right side 1 Turn signal light lead connector 2 E_4sv book Page 6 Friday November 10 2000 3 03 PM ...

Page 52: ...plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a distinctly dif ferent color th...

Page 53: ...l the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE _ If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ 4 Install the spark plug cap 5 Install the cowlings a Spark plug gap Spark pl...

Page 54: ...d then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil w...

Page 55: ...aced _ 5 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 6 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE _ Make sure that the O ring is properly seated _ 1 Engine oil drain bolt Left side 1 Oil filter cartridge 2 Oil filter wrench 1 O ring E_4sv book Page 10 Friday November 10 2000 3 03 PM...

Page 56: ...ot use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ 1 To...

Page 57: ...le on a level surface and hold it in an upright position NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should be between the ...

Page 58: ...therwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 42 for further instructions _ EAU03948 Cleaning the air filter element The air filter element should be c...

Page 59: ...G _ Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 5 Remove the air filter case cover by removing the screw 6 Pull the air filter element out 1 Screw 2 Air filter case cover 1 Air filter element E_4sv book Page 14 Friday November 10 2000 3 03 PM ...

Page 60: ... without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 9 Install the air filter case cover by installing the screw 10 Install the fuel tank by installing the bolts EW000072 WARNING _ Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a Yamaha dealer repla...

Page 61: ...dling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally revving it to 4 000 5 000 r min NOTE _ The engine is warm when it quickly re sponds to the throttle _ 2 Check the engine idling speed and if...

Page 62: ...ified in the periodic maintenance and lubrication chart EAU00658 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 EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when ...

Page 63: ...o not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride _ Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 250 kPa 2 50 kg...

Page 64: ... 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 with cast ...

Page 65: ...ed 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 The tires must be warmed up before a high speed run Always adjust the ...

Page 66: ... 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 EAU00715 Checking...

Page 67: ...ate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the res ervoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance 1...

Page 68: ... and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause Make sure to return the fluid reser voir diaphragm to the original shape before installing...

Page 69: ...he periodic maintenance and lubrica tion chart In addition have the oil seals of the master cylinder and caliper as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years Original shape E_4sv book Page 24 Friday November 10 2000 3 03 PM ...

Page 70: ...ing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU03608 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the ...

Page 71: ...d 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 EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging the O rings do not clean...

Page 72: ...ace a damaged cable as soon as possible to prevent unsafe conditions _ EAU03370 Checking and lubricating the brake 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 e...

Page 73: ...NING _ If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it _ EAU03166 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 grease all...

Page 74: ... 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 ...

Page 75: ...ha 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 E_4sv book Page 30 Friday November 10 2000 3 03 PM ...

Page 76: ...mpt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN _ To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the ...

Page 77: ...ages 3 11 and 6 5 for rider seat and cowling removal and installation procedures 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 EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electr...

Page 78: ...out replace it as follows 1 Disconnect the headlight and aux iliary light couplers and then re move the headlight 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 bulb into position and t...

Page 79: ...ght and auxilia ry light couplers 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU01823 Replacing the tail brake light bulb 1 Remove the passenger seat See page 3 11 for passenger seat re moval and installation proce dures 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the defective bulb by turning it counterclockwise 4 Insert a new bulb into t...

Page 80: ...er 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 motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the ...

Page 81: ...nt wheel axle pinch bolt then the wheel axle and the brake caliper bolts 4 Lift the front wheel off the ground according to the procedure on page 6 34 5 Remove the brake hose holders on each side by removing the bolts 6 Remove the brake calipers on each side by removing the bolts 7 Pull the wheel axle out remove the speedometer gear unit and then remove the wheel 1 Speedometer cable 2 Bolt 4 3 Fro...

Page 82: ... is on the ground 5 Install the brake calipers by install ing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs _ 6 Tighten the wheel axle then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 7 Connect the speedometer cable 8 Install the front fender by installing the bolts 9 ...

Page 83: ...r cycle so that there is no danger of it falling over _ 1 Loosen the axle nut and the brake caliper bolts 2 Lift the rear wheel off the ground according to the procedure on page 6 34 3 Remove the axle nut and then re move the brake caliper by remov ing the bolts 1 Axle nut 2 Drive chain slack adjusting bolt 3 Locknut 1 Bolt 2 2 Brake caliper E_4sv book Page 38 Friday November 10 2000 3 03 PM ...

Page 84: ...he brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut _ EAU03849 To install the rear wheel 1 Install the wheel by inserting the wheel axle from the right hand side 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 25 for drive chain slack adjustment pro cedures 3 Install the axle nut and t...

Page 85: ...xample can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imita...

Page 86: ... 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 Operate the electric starter 4 Battery The engine turns over quickly The engine t...

Page 87: ...iss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ NOTE _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Ch...

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Page 89: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 90: ...trical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners ...

Page 91: ...If the wind shield is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning...

Page 92: ...damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ 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 etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test its b...

Page 93: ...ent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore...

Page 94: ...every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see ...

Page 95: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 96: ...n ratio 11 5 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 3 0 L With oil filter cartridge replacement 3 2 L Total amount dry engine 3 5 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 ...

Page 97: ...system Chain drive Secondary reduction ratio 2 706 except for D F S SF 2 765 for D F S SF Number of drive chain sprocket teeth front rear 17 46 except for D F S SF 17 47 for D F S SF Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 571 2nd 1 778 3rd 1 381 4th 1 174 5th 1 037 Chassis Frame type Diamond Caster angle 24 Trail 97 mm Tires Front Type Tubeless tire Size 120 7...

Page 98: ...kg cm2 2 90 bar Rear 290 kPa 2 90 kg cm2 2 90 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 50 Rear Type Cast wheel Size 17 MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber F...

Page 99: ...r GB 12 V 35 35 W 2 for GB Auxiliary light 12 V 5 W 1 Tail brake light 12 V 5 21 W 2 Turn signal light 12 V 21 W 4 Meter lighting 12 V 1 7 W 4 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 1 Fuel level warning light 12 V 3 4 W 1 Fuses Main fuse 30 A Ignition fuse 15 A Signaling system fuse 15 ...

Page 100: ...O IMPERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kg m kg cm kg cm kg 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 101: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_4sv book Page 1 Friday November 10 2000 3 03 PM ...

Page 102: ... 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 y...

Page 103: ...under the rider seat See page 3 11 for rider seat removal and installation pro cedures Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_4sv book Page 2 Friday November 10 2000 3 03 PM ...

Page 104: ...ning light 3 3 Fuel tank breather hose 3 10 Fuel tank cap 3 9 Fuses replacing 6 32 H Handlebar switches 3 5 Headlight bulb replacing 6 33 Helmet holder 3 12 High beam indicator light 3 3 Horn switch 3 6 I Identification numbers 9 1 Idling speed adjusting 6 16 Ignition circuit cut off system 3 18 Indicator and warning lights 3 2 K Key identification number 9 1 L Light switch 3 6 Luggage strap holde...

Page 105: ...ree play adjusting 6 17 Tires 6 17 Tool kit 6 1 Troubleshooting 6 40 Troubleshooting charts 6 41 Turn signal indicator light 3 3 Turn signal light bulb replacing 6 35 Turn signal switch 3 6 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheel front 6 36 Installing 6 37 Removing 6 36 Wheel rear 6 38 Installing 6 39 Removing 6 38 Wheels 6 21 E_4sv b...

Page 106: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 107: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 108: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 10 0 3 1 CR E ...

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