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Yamaha V-Star XVS1100ATC Owner'S Manual Download Page 69

PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

EAU00692

Adjusting the clutch lever free 
play 

The clutch lever free play should mea-
sure 5–10 mm (0.2–0.4 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as
follows.

1. Loosen the locknut at the clutch

lever.

2. 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. 

_

EAU00696

Adjusting the brake lever free 
play 

The brake lever free play should mea-
sure 5–8 mm (0.2–0.3 in) as shown.
Periodically check the brake lever free
play and, if necessary, adjust it as
follows.

1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play

a. Brake lever free play

U5KS10.book  Page 19  Tuesday, November 5, 2002  11:05 AM

Summary of Contents for V-Star XVS1100ATC

Page 1: ...5KS 28199 10 LIT 11626 16 46 XVS1100AWR C XVS1100ATR C OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...s motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these...

Page 4: ... 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: ... TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ U5KS10 book Page 2 Tuesday November 5 2002 11 05 AM ...

Page 6: ...UAL 2002 by Yamaha Motor Corporation U S A 1st edition November 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 46 U5KS10 book Page 3 Tuesday November 5 2002 11 05 AM ...

Page 7: ...D 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 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 8: ...FORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

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

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

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

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

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

Page 14: ...uld catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If ...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5KS10 book Page 7 Tuesday November 5 2002 11 05 AM ...

Page 16: ...SAFETY INFORMATION 1 1 8 1 1 2 3 4 California only U5KS10 book Page 8 Tuesday November 5 2002 11 05 AM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 18: ...page 3 8 3 Shock absorber assembly spring preload adjusting ring page 3 14 4 Helmet holder page 3 11 5 Storage compartment page 3 11 6 Owner s tool kit page 6 1 7 Fuse box page 6 29 8 Engine oil level check window page 6 10 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 19: ...ION 2 2 2 Right view 9 Battery page 6 28 10 Main fuse page 6 30 11 Main switch steering lock page 3 1 12 Air filter element page 6 14 13 Brake pedal page 3 5 U5KS10 book Page 2 Tuesday November 5 2002 11 05 AM ...

Page 20: ...ge 3 4 2 Left handlebar switches page 3 3 3 Starter choke lever page 3 9 4 Speedometer unit page 3 3 5 Fuel tank cap page 3 6 6 Right handlebar switches page 3 4 7 Throttle grip page 6 15 8 Brake lever page 3 5 U5KS10 book Page 3 Tuesday November 5 2002 11 05 AM ...

Page 21: ...lever 3 4 Shift pedal 3 5 Brake lever 3 5 Brake pedal 3 5 Fuel tank cap 3 6 Fuel 3 7 Fuel cock 3 8 Starter choke lever 3 9 Seats 3 9 Helmet holder 3 11 Storage compartment 3 11 Adjusting the shock absorber assembly 3 13 Luggage strap holders 3 15 Sidestand 3 16 Ignition circuit cut off system 3 16 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 22: ...AU00040 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 while still pushing it EW000016 WARNING _ Never turn the key to OFF o...

Page 23: ...osition EAU00057 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU04585 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this oc curs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checke...

Page 24: ...st one second The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE _ This motorcycle is not equipped with a tachometer however it has a built in speed limiter which prevents the en gine speed from exceeding approxi mately 6 800 r min and the vehicle speed from exceeding approximately 175 km ...

Page 25: ...AU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION _ See page 5 1 for starting instruc tions prior to starting the engine _ EAU00152 Clutch lever T...

Page 26: ...is motorcycle NOTE _ Use your toes or heel to shift up and your toes to shift down _ EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 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 Shift pedal 1 Brake lever 1 Brake pedal ...

Page 27: ...ng with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE _ The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked _ EW000024 WARNING _ Make sure that the fuel tank cap is properly instal...

Page 28: ...ha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that...

Page 29: ...his position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON 1...

Page 30: ...turn off the starter choke ECA00038 CAUTION _ Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke _ EAU03202 Seats Passenger seat To remove the passenger seat Remove the bolt and then pull the pas senger seat up 1 Starter choke lever...

Page 31: ...ve the passenger seat 2 Remove the bolt and then pull the rider seat up To install the rider seat 1 Insert the projections on the front of the rider seat into the holders as shown place the seat in the origi nal position and then install the bolt 2 Install the passenger seat NOTE _ Make sure that the seats are properly secured before riding _ 1 Projection 2 Seat holder 1 Bolt 1 Projection 2 2 Seat...

Page 32: ...ached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident _ EAU01869 Storage compartment The storage compartment is located on the left side of the motorcycle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then turn it clockwise 1 Helmet holder 1 Storage compartment cover 2 Storage compartment lock cov...

Page 33: ...wn To close the storage compartment 1 Place the storage compartment cover in its original position as shown 2 Turn the key counterclockwise re move it and then close the lock cover 1 Storage compartment cover 1 Storage compartment cover U5KS10 book Page 12 Tuesday November 5 2002 11 05 AM ...

Page 34: ...ting mechanism beyond the maximum or minimum settings _ Adjust the spring preload as follows 1 Remove the rider seat See page 3 10 for rider seat removal and installation procedures 2 Remove each quick fastener from the ignitor unit panel by pushing the center in with a screwdriver then pulling the fastener out 3 Pull the ignitor unit panel out to the right 1 Quick fastener 3 1 Ignitor unit panel ...

Page 35: ... in direction b NOTE _ Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the adjustment _ CI 10E 6 Install the mudguard and ignitor unit panel by installing the quick fasteners 1 Quick fastener 3 2 Mudguard 1 Position indicator 2 Spring preload adjusting ring 3 Special wrench Setting ...

Page 36: ...nnot 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 shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always...

Page 37: ...illing 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 th...

Page 38: ...e 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 shoul...

Page 39: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 40: ...k oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 Final gear oil Check vehicle for oil leakage 6 12 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic...

Page 41: ...t operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switch...

Page 42: ...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 _ U5KS10 book Page 3 Tuesday November 5 2002 11 05 AM ...

Page 43: ...ERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 44: ... tor resulting in a possible loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04722 Starting and warming up a cold engine In order for the ignition ci...

Page 45: ... gine more than 10 seconds on any one attempt _ ECA00103 CAUTION _ The oil level warning light should come on when the key is turned to ON and then go off after two to three seconds If the oil level warning light flickers or remains on after starting imme diately stop the engine and then check the engine oil level and the vehicle for oil leakage If necessary add engine oil and then check the warni...

Page 46: ... F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position _ EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU00423 Shifti...

Page 47: ...tch lever slowly 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NO...

Page 48: ... full throttle operation or any condition that might result in engine overheating must be avoided EAU01171 0 1 000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 1 2 throttle EC000056 CAUTION _ After 1 000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter ele ment replaced _ 1 600 km 1 0...

Page 49: ...h and then turn the fuel cock lever to OFF 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 _ U5KS10 book Page 6 Tuesday November 5 2002 11 05 AM ...

Page 50: ... the brake pedal position 6 21 Adjusting the rear brake light switch 6 21 Checking the front and rear brake pads 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Checking and lubricating the cables 6 24 Checking and lubricating the throttle grip and cable 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Ch...

Page 51: ...LLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAIN...

Page 52: ... particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ U5KS10 book Page 2 Tuesday November 5 2002 11 05 AM ...

Page 53: ...tion Adjust gap and clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses for cracks or damage Replace if necessary 5 Fuel filter Replace initial 20 000 mi 31 000 km and thereafter every 20 000 mi 31 000 km 6 Ex...

Page 54: ...pads if necessary 5 Clutch Check operation Adjust or replace cable 6 Final gear oil Check oil level and leakage Replace at initial 600 mi 1 000 km or 1 month and thereafter every 16 000 mi 25 000 km or 24 months Hypoid gear oil SAE 80 API GL4 Replace Check 7 Control and meter cables Apply chain lube thoroughly Yamaha Chain and Cable Lube or engine oil SAE10W 30 API SE 8 Swingarm pivot shaft Check ...

Page 55: ... looseness and damage Replace if necessary 16 Wheels Check runout and for damage 17 Sidestand switch Check operation Replace if necessary 18 Tires Check tire tread wear and for damage Replace if necessary 19 Shock absorber assembly Check operation and for oil leakage Replace if necessary 20 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary 21 Th...

Page 56: ... in unusually wet or dusty areas Hydraulic brake service After 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 Replace the brake hoses every four years and if cracked or damaged...

Page 57: ...nance jobs described in this chapter Refer to this section each time the pan el needs to be removed and installed EAU00491 Panel A To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 1 Bolt U5KS10 book Page 7 Tuesday November 5 2002 11 05 AM ...

Page 58: ...g 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 the e...

Page 59: ...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 Place the spark plug cover in the original position EAU01796 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Check each hose connection Check ...

Page 60: ...nutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case 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 engi...

Page 61: ...se oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 6 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 Engine ...

Page 62: ...ked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart EW000066 WARNING _ Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel _ To check the final gear oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ The final gear oil level must be check...

Page 63: ...s rated GL5 or GL6 may also be used _ 5 Install and tighten the oil filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause EAU03195 Cleaning the air filter element The air filter element should be cleaned as follows at the intervals specified in the periodic maintenance and lubrica tion chart Clean the air filter element more frequently if you are riding in u...

Page 64: ... The engine should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 5 Install the air filter case cover by installing the screws EAU00628 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustm...

Page 65: ...s specified in the periodic maintenance and lubrication chart EAU04855 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...

Page 66: ... this model does not exceed the maxi mum load of the motorcycle Opera tion of an overloaded motorcycle could cause tire damage an acci dent or even injury _ Tire inspection Always check the tires before operating the motorcycle If a tire tread shows 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...

Page 67: ...cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An un...

Page 68: ...e orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot con trol the quality of accessories or parts manufactured by other c...

Page 69: ...r 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 _ EAU00696 Adjusting the brake lever free play The brake lever free play should mea sure 5 8 mm 0 2 0 3 in as shown Periodically check the brake lever fr...

Page 70: ... 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 ...

Page 71: ...lic 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 72: ... with a wear indicator groove which allows you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set 1 Brake pad wear indicator groove Front 1 Brake pad wear indicator groove Rear...

Page 73: ...he 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 lock Brake fluid may de...

Page 74: ...ould be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000111 WARNING _ Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions _ EAU04...

Page 75: ...ould be lu bricated if necessary EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING _ If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it _ Recommended lubricant Lithium soap based greas...

Page 76: ...000115 WARNING _ Securely support the motorcycle so that there is no danger of it falling over _ Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds s...

Page 77: ...upport the motorcycle so that there is no danger of it falling over _ 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the 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 cha...

Page 78: ...f water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt 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 d...

Page 79: ...ttery If you do not have ac cess to a sealed type MF bat tery charger have a Yamaha dealer charge your battery _ EAU04210 Replacing the fuses The main fuse is located under the igni tor unit panel The fuse box which contains the fuses for the individual circuits is located in side the storage compartment See page 3 11 for storage compartment cover removal and installation proce dures 1 Positive te...

Page 80: ...ll 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 _ 6 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 7 If the fuse immediately blows again have a Yamaha dealer check the electrical system 8 Install...

Page 81: ...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 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...

Page 82: ...e will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol 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 1 Do not touch the glass part of the bulb U5KS10 book Page 32 Tuesday ...

Page 83: ...is model is not equipped with 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 t...

Page 84: ...Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting 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 motorc...

Page 85: ...gnition 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 engine turns over ...

Page 86: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 87: ...l 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 and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners especially on ...

Page 88: ...eld 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 After riding i...

Page 89: ... surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 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 riding at higher speeds test the motorcycle s braking performance and cor nering ...

Page 90: ...to 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 c Install the spark plug caps onto the spark plugs and the...

Page 91: ...one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 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 30 F or more than 30 C 90 F For more informa tion on storing the battery see page 6 28 NOTE _ Make any necessary repairs before sto...

Page 92: ...SPECIFICATIONS 8 Specifications 8 1 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 93: ...r Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 3 0 L 2 64 Imp qt 3 17 US qt With oil filter element replacement 3 1 L 2 73 Imp qt 3 28 US qt Total amount dry engine 3 6 L 3 17 Imp qt 3 81 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0 10 20 30 40 50 C YAMALU...

Page 94: ... 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 660 Secondary reduction system Shaft drive Secondary reduction ratio 2 875 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 353 2nd 1 667 3rd 1 286 4th 1 032 5th 0 853 Chassis Frame type Double cradle Caster angle 33 Trail 132 mm 5 2 in Tires Front Type Tubel...

Page 95: ...ize 15 M C MT 4 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 Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 140 mm 5 51 in Rear 113 mm 4 45 in Electrical Ignition system T C I digital Charging sys...

Page 96: ...ng 14 V 1 4 W 2 Oil level warning light 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 1 Engine trouble warning light 12 V 1 7 W 1 High beam indicator light 12 V 1 7 W 1 Fuses Main fuse 30 A Signaling system fuse 10 A Backup fuse odometer 5 A Ignition fuse 10 A Headlight fuse 15 A Carburetor heater fuse 15 A U5KS10 book Page 4 Tuesday November 5 2002 11 05...

Page 97: ...r 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5KS10 book Page 1 Tuesday November 5 2002 11 05 AM ...

Page 98: ... 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 provided NOTE _ The vehicle identification number is used to identify yo...

Page 99: ...under the rider seat See page 3 10 for rider seat removal and installation procedures 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 U5KS10 book Page 2 Tuesday November 5 2002 11 05 AM ...

Page 100: ...tigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tran...

Page 101: ...for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 01E...

Page 102: ...printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi ...

Page 103: ...r 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5KS10 book Page 6 Tuesday November 5 2002 11 05 AM ...

Page 104: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5KS10 book Page 7 Tuesday November 5 2002 11 05 AM ...

Page 105: ...CONSUMER INFORMATION 9 8 9 U5KS10 book Page 8 Tuesday November 5 2002 11 05 AM ...

Page 106: ...pairs 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 phon...

Page 107: ...rotection 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 E_5ks_Consumer fm Page 10 Wednesday November 6 2002 2 46 PM ...

Page 108: ...1 High beam indicator light 3 2 Horn switch 3 3 I Identification numbers 9 1 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 Luggage strap holders 3 15 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 Model label...

Page 109: ...ing and lubricating 6 24 Tires 6 15 Tool kit 6 1 Troubleshooting 6 34 Troubleshooting chart 6 35 Turn signal indicator light 3 2 Turn signal light or tail brake light bulb replacing 6 33 Turn signal switch 3 4 V Valve clearance adjusting 6 15 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 27 Wheels 6 17 U5KS10 book Page 2 Tuesday November 5...

Page 110: ...PRINTED IN JAPAN 2002 11 2 7 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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