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Yamaha Venture XVZ1300TF, Owner'S Manual

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Yamaha Venture XVZ1300TF Owner'S Manual Download Page 73

7

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit  ....................................................7-1

Periodic maintenance and lubrication chart .........7-3

Removing and installing cowlings and panels  .....7-6

Checking the spark plugs  ..................................7-11

Engine oil and oil filter cartridge  ........................7-12

Final gear oil  ......................................................7-15

Checking the coolant level  .................................7-15

Cleaning the air filter elements  ..........................7-17

Adjusting the carburetors ...................................7-19

Adjusting the engine idling speed  ......................7-20

Adjusting the throttle cable free play ..................7-21

Adjusting the valve clearance  ............................7-21

Tires ...................................................................7-21

Cast wheels  .......................................................7-24

Clutch lever free play  .........................................7-25

Adjusting the brake lever free play .....................7-25

Adjusting the brake pedal position .....................7-26

Adjusting the rear brake light switch  ..................7-26

Checking the front and rear brake pads  ............ 7-27

Checking the brake and clutch fluid levels  ........ 7-28

Changing the brake and clutch fluids  ................ 7-29

Checking and lubricating the brake and 

shift pedals  ...................................................... 7-29

Checking and lubricating the brake and 

clutch levers  .................................................... 7-30

Checking and lubricating the sidestand  ............ 7-30

Checking the front fork  ...................................... 7-31

Checking the steering  ....................................... 7-31

Battery ............................................................... 7-32

Replacing the fuses  .......................................... 7-33

Replacing the headlight bulb ............................. 7-35

Replacing a turn signal light bulb or the 

tail/brake light bulb  .......................................... 7-36

Replacing the license plate light bulb ................ 7-37

Troubleshooting ................................................. 7-37

Troubleshooting charts  ...................................... 7-38

E_5jc.book  Page 1  Monday, January 22, 2001  12:12 PM

Summary of Contents for Venture XVZ1300TF

Page 1: ...XVZ1300TF OWNER S MANUAL ...

Page 2: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 3: ...to enjoy all advantages of your Royal Star VENTURE 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 others 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 ...

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_5jc book Page 2 Monday January 22 2001 12 12 PM ...

Page 6: ...ANUAL 2000 by Yamaha Motor Co Ltd 1st Edition November 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_5jc book Page 3 Monday January 22 2001 12 12 PM ...

Page 7: ...ND CONTROL FUNCTIONS 3 4 AUDIO SYSTEM 4 5 PRE OPERATION CHECKS 5 6 OPERATION AND IMPORTANT RIDING POINTS 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR 7 8 MOTORCYCLE CARE AND STORAGE 8 9 SPECIFICATIONS 9 10 CONSUMER INFORMATION 10 INDEX E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 8: ...E_5jc book Page 2 Monday January 22 2001 12 12 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_5jc book Page 1 Monday January 22 2001 12 12 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 passen gers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic mate rials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however shou...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 12: ...e 3 14 3 Fuel tank cap page 3 11 4 Fuel cock page 3 13 5 Battery page 7 32 6 Fuse box 2 page 7 34 7 Side case page 3 17 8 Helmet holder page 3 15 9 License light page 7 37 10 Tail brake light page 7 36 11 Rear turn signal lights page 7 36 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 13: ... valve page 3 20 18 Rider seat page 3 15 19 Fuel tank page 3 12 20 Front fork air valve page 3 19 21 Headlight page 7 35 22 Front turn signal lights page 7 36 23 Fuse box 1 page 7 33 24 Brake pedal page 3 11 25 Engine oil level check window page 7 12 26 Rider footrest 27 Coolant reservoir page 7 15 28 Passenger footrest E_5jc book Page 2 Monday January 22 2001 12 12 PM ...

Page 14: ...ontrol unit page 4 3 3 Left handlebar switches page 3 9 4 Rider headset jack page 4 2 5 Speedometer unit page 3 5 6 Main switch steering lock page 3 1 7 Right handlebar switches page 3 9 8 Throttle grip page 7 21 9 Brake lever page 3 11 E_5jc book Page 3 Monday January 22 2001 12 12 PM ...

Page 15: ...rake lever 3 11 Brake pedal 3 11 Fuel tank cap 3 11 Fuel 3 12 Fuel tank breather hose 3 13 Fuel cock 3 13 Starter choke knob 3 14 Locking the steering with a padlock 3 14 Rider seat 3 15 Helmet holders 3 15 Side cases and travel trunk 3 16 Adjusting the front fork 3 19 Adjusting the shock absorber assembly 3 20 Sidestand 3 21 Ignition circuit cut off system 3 22 Auxiliary DC jack and terminals 3 2...

Page 16: ...n Therefore do not use the ac cessory position for an extended period of time otherwise the battery may dis charge The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed EAU00040 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 OF...

Page 17: ... is stopped before turning the key to OFF or LOCK 1 Push 2 Turn EAU01861 Parking The steering is locked and the taillight license light and auxiliary light are on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to ECA00043 CAUTION _ Do not use the parking position for an extended length of time other wise the battery may disc...

Page 18: ...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 electri cal 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 E...

Page 19: ...on EAU01707 9 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool 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 l...

Page 20: ...e distance traveled from that point In that case pushing the SELECT button switches the dis play between the various tripmeter and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F To reset a tripmeter select it by push ing the SELECT button and then push the RESET button If you do not reset the fuel reserve tripmeter manu ally it will reset itself automatically and the display...

Page 21: ... be sure to push the SELECT button before turning the key to OFF otherwise the clock will not be set EAU04037 Cruise control system This motorcycle is equipped with a cruise control system designed to maintain a set traveling speed Activating and setting the cruise control system The cruise control system can only be activated when riding in 4th or 5th gear at speeds between 50 km h and 130 km h T...

Page 22: ...and the throttle grip is turned to increase the speed by up to 8 km h the cruise control system will return to the set speed after the throttle grip is re leased However if the speed is in creased by more than 8 km h the cruise control system will be deactivat ed until the traveling speed is within 8 km h of the set speed Deactivating the cruise control system Applying the front or rear brake or d...

Page 23: ...cruise control system off and have a Yamaha deal er check it _ EAU01779 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The display seg ments of the fuel gauge disappear to wards E Empty as the fuel level decreases When only one segment is left near E refuel as soon as possi ble NOTE This fuel gauge is equipped with a self diagnosis system If the electrical cir cuit is defe...

Page 24: ... signal lights push the switch in after it has re turned to the center position EAU00129 4 Horn switch Press this switch to sound the horn EAU03890 5 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 EAU03966 6 Light switch Set this switch to to t...

Page 25: ...he clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 22 for an explanation of the ignition circuit cut off system EAU01215 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with th...

Page 26: ... down on the brake pedal EAU02917 Fuel tank cap To remove the fuel tank cap Slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 1 Brake lever 1 Brake pe...

Page 27: ...ttom of the filler tube as shown EW000130 WARNING _ Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION _ Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts _ EAU00191 NOTE _ If knocking or pinging occurs use gasoline of a differe...

Page 28: ...s fuel from the tank to the carburetors while also filter ing it The fuel cock lever positions are ex plained as follows and shown in the il lustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the en gine is not running ON With the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever t...

Page 29: ... air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke EAU03372 Locking the steering with a padlock In addition to the main switch steering lock there are brackets on the right side of the steering head pipe for lock ing the steering with a padlock To do so turn the handlebar unti...

Page 30: ...r seat into the seat holder as shown place the seat in the original position and then tighten the nuts NOTE Make sure that the rider seat is proper ly secured before riding EAU01782 Helmet holders To open a helmet holder Insert the key into the helmet holder lock and then turn it as shown 1 Nut 2 1 Projection 2 Seat holder 1 Helmet holder right 2 Unlock E_5jc book Page 15 Monday January 22 2001 12...

Page 31: ...nt loading and tire pressure information Always securely close the side cases and travel trunk before riding Distribute weight evenly on each side of the motorcycle Do not exceed the load limit of 9 kg for each side case and the travel trunk Do not exceed the maximum load of 190 kg for the vehicle Do not exceed 120 km h when riding with the travel trunk side cases or both installed other wise hand...

Page 32: ...old the side case lid down 2 Turn the key clockwise and then remove it NOTE Push both sides of the lid down so that both latches snap into place Travel trunk To open the travel trunk 1 Insert the key into the lock turn it counterclockwise and then push it in 1 Side case lock 2 Unlock 1 Main storage area 2 Storage pouch 1 Travel trunk lock 2 Unlock E_5jc book Page 17 Monday January 22 2001 12 12 PM...

Page 33: ... 1 Fold the travel trunk lid up com pletely and then fold it down NOTE Push both sides of the lid down so that both latches snap into place 2 Turn the key clockwise and then remove it ECA00030 CAUTION To avoid locking the key in never lock either side case or the travel trunk and remove the key from the lock before closing the lid 1 Travel trunk lid resting in opened position 2 Storage pouch E_5jc...

Page 34: ...ressure in each fork leg with the air pressure gauge included in the owner s tool kit 4 To increase the spring rate and thereby harden the suspension increase the air pressure with an air pump To decrease the spring rate and thereby soften the sus pension decrease the air pres sure by pushing each valve stem down EC000012 CAUTION _ Never exceed the maximum air pres sure otherwise the front fork oi...

Page 35: ...be no weight on the motorcycle _ 2 Remove the air valve cap 3 Check the air pressure with the air pressure gauge included in the owner s tool kit 4 To increase the spring rate and thereby harden the suspension in crease the air pressure with an air pump To decrease the spring rate and thereby soften the suspen sion decrease the air pressure by pushing the valve stem down 1 Shock absorber assembly ...

Page 36: ...e further down 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 assis...

Page 37: ...he 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 38: ...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 39: ...ION The accessories connected to the auxiliary DC jack and terminals should not be used with the engine turned off and their combined load must never exceed 5 A or 60 W oth erwise the battery may discharge EWA00017 WARNING To prevent electrical shock or short circuiting make sure that the caps are installed when the auxiliary DC jack and terminals are not being used 1 Auxiliary DC jack 1 Auxiliary...

Page 40: ...E_5jc book Page 25 Monday January 22 2001 12 12 PM ...

Page 41: ...tional 4 2 Control unit 4 3 Making basic settings 4 5 Making mode settings 4 5 Cassette deck operation 4 9 Radio operation 4 12 Optional CD changer operation 4 17 Auxiliary audio source operation 4 18 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 42: ...Front speaker 2 3 Rider headset jack 4 Cassette deck lid 5 Main switch steering lock 6 Eject button 7 Cassette deck compartment 8 Auxiliary audio input jack 1 Rear speaker 2 2 Passenger volume control knob 3 Passenger headset jack E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 43: ...owever it is good prac tice to cover them with a plastic bag when washing the motor cycle When cleaning the control unit display use a neutral detergent Never use strong abrasive cleaning products fuel gaso line thinner etc _ Headsets optional For intercom use two headsets are necessary Consult a Yamaha dealer if you wish to obtain headsets Connect the headsets to the jacks shown in the illustrati...

Page 44: ...he cassette deck play direction Tuning in a radio station automati cally Selecting a CD in the optional CD changer Audio system button AUDIO This button is used to perform the fol lowing operations Short push less than one second Turning on the audio system Changing the audio source in the following sequence Long push one second or more Turning off the audio system 1 Volume control knob 2 Up down ...

Page 45: ...sh two seconds or more Selecting the preset radio station programming mode Output BASS TREB FAD Auto volume Intercom volume Radio SP HS Treble frequency Fade 1 2 IC AV 1 2 This mode does not appear in the display when the headsets are selected as the output This mode appears in the display only when one of the radio frequency bands is selected as the au dio source E_5jc book Page 4 Monday January ...

Page 46: ... made the audio system returns to normal op eration and the current audio mode ap pears in the display Making mode settings General procedure The following setting procedure applies to the audio system and optional CD changer NOTE _ In order to make settings in any of the audio system modes make sure that the audio system is selected If neces sary push the AUDIO button for less than one second _ 1...

Page 47: ...d headsets cannot be used at the same time _ Adjusting the bass level 1 Repeatedly push the SELECT button for less than one second until BASS appears at the bot tom of the display 2 Repeatedly push either side of the up down switch for less than one second until the desired level is displayed The bass level can be set between 6 and 6 Output BASS TREB FAD Auto volume Intercom volume Radio SP HS Tre...

Page 48: ...1 Make sure that the speakers are selected as the output source See the Selecting the output section on page 4 6 for selection procedures 2 Repeatedly push the SELECT button for less than one second until FAD appears at the bottom of the display 3 Repeatedly push either side of the up down switch for less than one second until the desired level is displayed The fade level can be set between F9 fro...

Page 49: ... override the audio system output volume The audio system fea tures an automatic volume control function which compensates for exter nal noise 1 Repeatedly push the SELECT button for less than one second until the auto volume e g AV 3 appears in the display 2 Repeatedly push either side of the up down switch for less than one second until the desired volume is displayed The auto volume can be set ...

Page 50: ...times except when inserting or removing a cas sette Do not leave cassette tapes in direct sunlight for a long period of time Do not allow the inside of the cassette deck to get wet If this happens keep the cassette deck lid open and dry out the deck in the shade To clean the tape head use a de magnetizing cleaning cas sette but be sure to turn the volume all the way down to avoid speaker damage _ ...

Page 51: ...han one second for each song to be skipped Pushing skips songs in the forward direction Pushing skips songs in the reverse direc tion APC auto program control and the number of songs to be skipped e g 3 appear in the display When skipping songs in reverse a minus sign appears in front of the number of songs to be skipped e g 2 1 indicates that the current song will be played again NOTE _ The maxim...

Page 52: ...r more than one second to reverse the play direction F appears in the display when the tape is played in the forward direction R appears in the display when the tape is played in the reverse direction Turning on off the Dolby noise reduction system While the cassette tape is playing push the eject button for more than two seconds to turn the Dolby B noise reduction system on or off B NR ap pears i...

Page 53: ...the eject button to eject the tape from the cassette deck EJCT appears in the display and then CASS starts flashing Radio operation WARNING _ It is dangerous to operate the radio while riding Never take your hands off the handlebars while riding Keep the volume at a low enough level to be aware of traf fic conditions and ensure safe ty Never ride the motorcycle with the radio antenna folded down _...

Page 54: ...o rizing FM preset stations Repeatedly push the AUDIO button for less than one second until the desired frequency band appears in the display Tuning in a radio station automatically 1 Select a frequency band 2 Push either side of the up down switch once for one second or more The radio automatically tunes in the first station that has a strong enough signal to be re ceived 1 Antenna sleeve 1 Frequ...

Page 55: ...ush either side of the up down switch for less than one second until the desired frequency is dis played The frequency changes in 0 2 MHz steps for FM and in 10 kHz steps for AM Tuning in a preset radio station 1 Select a frequency band See page 4 13 2 Repeatedly push either side of the up down switch for less than one second until the desired preset station number is displayed NOTE _ To be able t...

Page 56: ...on once for less than one second to store the radio station selected in step 1 under the preset number selected in step 3 5 Repeat this procedure to preset other radio stations Using automatic tuning 1 Select a frequency band See page 4 13 2 Push the SELECT button once for two seconds or more The ra dio frequency and preset station number 1 to the right of CH start flashing 3 Push either side of t...

Page 57: ...lect a frequency band See page 4 13 2 Push the SELECT button once for two seconds or more The ra dio frequency and preset station number 1 to the right of CH start flashing 3 Repeatedly push either side of the up down switch for less than one second until A automatic ap pears in the display 4 Push the SELECT button once for less than one second to pro gram preset radio stations auto matically E_5j...

Page 58: ...1 Insert up to six CDs into the CD changer Follow the manufactur er s directions 2 Push the AUDIO button until as well as the CD number and track number e g 6 3 ap pear in the display The CD starts playing NOTE _ 6 3 indicates track no 3 on CD no 6 _ Selecting a CD Repeatedly push either side of the up down switch for one second or more until the number for the desired CD ap pears in the display S...

Page 59: ...rt the output plug of the auxil iary equipment into the jack locat ed at the right of the cassette deck 2 Repeatedly push the AUDIO but ton for less than one second until AUX appears in the display The auxiliary equipment can now be played through the audio system 1 Auxiliary audio input jack E_5jc book Page 18 Monday January 22 2001 12 12 PM ...

Page 60: ...E_5jc book Page 19 Monday January 22 2001 12 12 PM ...

Page 61: ...PRE OPERATION CHECKS 5 Pre operation check list 5 1 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 62: ... engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 12 Final gear oil Check vehicle for oil leakage 7 15 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 7 15 7 16 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjus...

Page 63: ...on and tread depth Check air pressure Correct if necessary 7 21 7 24 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 29 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 30 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 30 Chassis fasteners Make sure that al...

Page 64: ...ection 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 E_5jc book Page 3 Monday January 22 2001 12 12 PM ...

Page 65: ...S 6 Starting the engine 6 1 Starting a warm engine 6 3 Shifting 6 3 Recommended shift points for Switzerland only 6 4 Tips for reducing fuel consumption 6 4 Engine break in 6 5 Parking 6 6 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 66: ... Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU03970 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is i...

Page 67: ...e neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 4 Turn the starter choke on and completely close the throttle See page 3 14 for starter choke oper ation 5 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt shou...

Page 68: ... 7 When the engine is warm turn the starter choke off NOTE _ The engine is warm when it responds normally to the throttle with the starter choke turned off _ 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 Shifting Shifting gears lets you control the amount of engine ...

Page 69: ...re shown in the table be low CF 01E NOTE _ When shifting down two gears at a time reduce the speed accordingly e g down to 35 km h when shifting from 4th to 2nd gear _ EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Thoroughly warm up the engine Turn the starter choke off as soon as possible Sh...

Page 70: ...ing this period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU01171 0 1 000 km Avoid prolonged operation above 1 3 throttle 1 000 1 600 km Avoid prolonged operation above 1 2 throttle EC000056 CAUTION After 1 000 km of operation the en gine oil and final gear oil must be changed and the oil filter cartridge replaced 1 600 km and beyo...

Page 71: ...itch 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 E_5jc book Page 6 Monday January 22 2001 12 12 PM ...

Page 72: ...E_5jc book Page 7 Monday January 22 2001 12 12 PM ...

Page 73: ...ake lever free play 7 25 Adjusting the brake pedal position 7 26 Adjusting the rear brake light switch 7 26 Checking the front and rear brake pads 7 27 Checking the brake and clutch fluid levels 7 28 Changing the brake and clutch fluids 7 29 Checking and lubricating the brake and shift pedals 7 29 Checking and lubricating the brake and clutch levers 7 30 Checking and lubricating the sidestand 7 30...

Page 74: ...TERRAIN GEOGRAPHI CAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORT ENED EW000060 WARNING _ If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you _ EAU03568 Owner s tool kit The owner s tool kit is located inside the right side case See page 3 17 for side case opening procedures The service information included in this manual and...

Page 75: ...equired for a particular job have a Yamaha dealer perform it for you EW000063 WARNING Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle unsafe for use Consult a Yamaha dealer be fore attempting any changes E_5jc book Page 2 Monday January 22 2001 12 12 PM ...

Page 76: ...ine 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 7 5 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 7 5 Repl...

Page 77: ...crews 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 grease 21 Carburetors Check starter choke operation Ad...

Page 78: ... required Replace the oil seals on the inner 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 _ 25 Final gear oil Check oil level and vehicle for oil leakage Change 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights sig...

Page 79: ...ch time a cowling or panel needs to be re moved and installed EAU04039 Cowling A To remove the cowling 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 _ 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 3 Panel C 1 Cowling A 2 Screw 2 3 Quick fastener E_5jc...

Page 80: ... the projection fits into the grommet To install the quick fastener push the center pin out so that it will pro trude from the fastener head in sert the fastener into the cowling and then push the protruding pin in until it is flush with the fastener head _ 1 Screw 1 Grommet 2 Projection 3 Cowling A After removal Before installation E_5jc book Page 7 Monday January 22 2001 12 12 PM ...

Page 81: ...emove the screws and then pull the cowling off as shown To install the cowling 1 Place the cowling in the original position and then install the screws NOTE Make sure that the projection fits into the grommet 2 Install cowling A 1 Cowling B 2 Screw 2 1 Screw E_5jc book Page 8 Monday January 22 2001 12 12 PM ...

Page 82: ...nd then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw EAU00488 Panel B To remove the panel Remove the screw and then pull the panel off as shown 1 Panel A 2 Screw 1 Panel B 2 Screw E_5jc book Page 9 Monday January 22 2001 12 12 PM ...

Page 83: ...move the panel 1 Remove the left passenger foot rest by removing the bolts 2 Remove the screw and then pull the panel off as shown To install the panel 1 Place the panel in the original po sition and then install the screw 2 Install the passenger footrest by installing the bolts 1 Panel C 2 Screw 3 Bolt 2 E_5jc book Page 10 Monday January 22 2001 12 12 PM ...

Page 84: ...lor 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 plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surfa...

Page 85: ... engine warm it up for several minutes 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 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 cor...

Page 86: ... engine oil to the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 6 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque 1 Engine oil drain bolt 1 Engine oil filter cartridge 1 Torque wrench 2 Oil filter wrench Tightening torque ...

Page 87: ...t 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 EC000067 CAUTION If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle 10 Tu...

Page 88: ...c mainte nance and lubrication chart 1 Place the motorcycle on a level surface and hold it in an upright position 2 Remove panel A See page 7 9 for panel removal and installation procedures 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 ...

Page 89: ...ool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap...

Page 90: ...ements more frequently if you are riding in unusually wet or dusty areas 1 Remove cowlings A and B See pages 7 6 7 8 for cowling removal and installation procedures NOTE Continue as follows for each air filter element 2 Remove the air filter case by re moving the bolts 3 Loosen the air filter joint clamp screw and then pull the air filter off 1 Air filter case 2 Bolt 2 1 Screw E_5jc book Page 17 M...

Page 91: ...lement by removing the screws 6 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 1 Bolt 5 1 Air filter element 2 Screw 2 1 Air filter element E_5jc book Page 18 Monday January 22 2001 12 12 PM ...

Page 92: ...tall the air filter case by install ing the bolts 11 Install the cowlings NOTE Make sure that the air filter case drain hose is routed as shown EAU00630 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe ...

Page 93: ...t 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 _ 3 Check the engine idling speed and if necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the engine idling speed turn the screw in di rection b NOTE _ If the...

Page 94: ...ing in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU03975 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 pr...

Page 95: ...al weight of the cargo rider passenger and accessories cowling side cases etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury _ Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragmen...

Page 96: ...orcycle is equipped with tube less tires tire air valves and cast wheels EW000132 WARNING _ The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely install...

Page 97: ...An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics After repairing or replacing the rear tire tighten the valve stem nut and locknut to the specified torques FRONT Manufacturer Size Type Dunlop 150 ...

Page 98: ...check the brake lever free play and if necessary adjust it as follows 1 Loosen the locknut at the brake lever 2 To increase the brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut EW000099 WARNING After adjusting the brake lever free play check the free play and make sure that the brake is ...

Page 99: ...ve a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident EAU01799 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 Since the brake...

Page 100: ...es If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU03939 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has...

Page 101: ...uali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance Be careful that water does not en ter the brake or clutch fluid reser voir when refilling Water will significantly lower the boiling poin...

Page 102: ...i pers as well as the brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years 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 necessar...

Page 103: ...ating 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 grease all purpose grease Recommended lubricant Lithium soap based gre...

Page 104: ...on 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 ch...

Page 105: ...since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical att...

Page 106: ... battery leads are properly con nected to the battery terminals EC000102 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have ac cess to a sealed type MF bat tery charger have a ...

Page 107: ... rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 1 Odometer fuse 2 Radiator fan fuse 3 Headlight fuse 4 Signaling system fuse 5 Ignition fuse 6 Spare fuse 2 1 Main fuse 2 Spare main fuse Specified fuses Fuse box 1 Cruise control fuse 10 A Carburetor heater fuse 10 A Auxiliary DC terminal fuse 5 A Auxiliary DC jack fuse 5 A Audio system fuse 10...

Page 108: ...out replace it as follows 1 Disconnect the headlight coupler and then remove the headlight bulb cover 2 Remove the headlight bulb holder by turning it counterclockwise 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 a...

Page 109: ...r and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU00855 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by ins...

Page 110: ...h inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example 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 t...

Page 111: ...ompression 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 tur...

Page 112: ... hiss 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 Check ...

Page 113: ...MOTORCYCLE CARE AND STORAGE 8 Care 8 1 Storage 8 4 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 114: ...n 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 ECA00036 CAUTION _ Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner...

Page 115: ...ompound 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 in the rain near the sea or on salt sprayed roads Si...

Page 116: ...ainted surfaces 7 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 braking perfor mance and cornering behav...

Page 117: ...e carburetor float chamber by loosening the drain bolt this will prevent 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 spa...

Page 118: ...s 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 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...

Page 119: ...SPECIFICATIONS 9 Specifications 9 1 Conversion table 9 5 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 120: ...ng 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 5 L With oil filter cartridge replacement 3 7 L Total amount dry engine 4 3 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 cont...

Page 121: ...et multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 776 Secondary reduction system Shaft drive Secondary reduction ratio 2 567 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 529 2nd 1 632 3rd 1 200 4th 0 960 5th 0 786 Chassis Frame type Double cradle Caster angle 29 17 Trail 152 mm Tire Front Type Tubeless tire Size 150 80 16 71H...

Page 122: ...5M C MT 4 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 link suspension Spring shock absorber Front Coil air spring oil damper Rear Coil air spring oil damper Wheel travel Front 140 mm Rear 105 mm Electrical Ignition system T C I digital Charging system Type A C magne...

Page 123: ... light 12 V 1 7 W 1 Overdrive indicator light 12 V 1 7 W 1 Cruise control SET indicator light 12 V 1 7 W 1 Cruise control RES indicator light 12 V 1 7 W 1 Cruise control ON indicator light 12 V 1 7 W 1 Audio system amplifier Output power Speaker 14 W 4 Headset 1 W 2 Auto volume range 5 steps Output impedance Speaker 4 Ω Headset 8 16 Ω Fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse ...

Page 124: ...MPERIAL 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 k...

Page 125: ...CONSUMER INFORMATION 10 Identification numbers 10 1 Key identification number 10 1 Vehicle identification number 10 1 Model label 10 2 E_5jc book Page 1 Monday January 22 2001 12 12 PM ...

Page 126: ... 01E 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 ...

Page 127: ... under the rider seat See page 3 15 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_5jc book Page 2 Monday January 22 2001 12 12 PM ...

Page 128: ...3 10 Cruise control system 3 6 D Dimmer switch 3 9 E Engine break in 6 5 Engine oil and oil filter cartridge 7 12 Engine stop switch 3 9 Engine trouble warning light 3 3 F Final gear oil 7 15 Front fork adjusting 3 19 Front fork checking 7 31 Fuel 3 12 Fuel cock 3 13 Fuel consumption tips for reducing 6 4 Fuel gauge 3 8 Fuel level warning light 3 4 Fuel tank breather hose 3 13 Fuel tank cap 3 11 F...

Page 129: ...ter choke knob 3 14 Starting a warm engine 6 3 Starting the engine 6 1 Start switch 3 10 Steering checking 7 31 Steering locking with a padlock 3 14 Storage 8 4 T Throttle cable free play adjusting 7 21 Tires 7 21 Tool kit 7 1 Troubleshooting 7 37 Troubleshooting charts 7 38 Turn signal indicator lights 3 3 Turn signal light or tail brake light bulb replacing 7 36 Turn signal switch 3 9 V Valve cl...

Page 130: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 131: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

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