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Yamaha WARRIOR XV17PCT, Owner'S Manual

The Yamaha WARRIOR XV17PCT is a powerful and sleek motorcycle designed for riders seeking a thrilling adventure on the road. To ensure a safe and optimal riding experience, we provide a comprehensive Owner's Manual that can be downloaded for free from manualshive.com. Explore your motorcycle's capabilities with our detailed manual.

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INDEX

A

Accessories and replacement parts ..... 6-20
Air filter elements, replacing ................. 6-13

B

Battery .................................................. 6-31
Brake and clutch levers, checking and 

lubricating ........................................... 6-28

Brake and shift pedals, checking and 

lubricating ........................................... 6-27

Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever ............................................. 3-7
Brake lever free play, adjusting ............ 6-21
Brake pedal ............................................ 3-7

C

Cables, checking and lubricating .......... 6-26
Canister (for California only)................... 6-9
Care ........................................................ 7-1
Clutch lever............................................. 3-6
Clutch lever free play, adjusting ........... 6-20

D

Dimmer switch ........................................ 3-5
Drive belt slack ..................................... 6-25

E

Engine break-in ...................................... 5-3
Engine oil and oil filter cartridge ............. 6-9
Engine stop switch.................................. 3-6
Engine trouble warning light ................... 3-2

F

Front and rear brake pads, checking .... 6-22
Front fork, adjusting .............................. 3-10
Front fork, checking .............................. 6-29
Fuel......................................................... 3-8
Fuel level warning light ........................... 3-2

Fuel tank cap...........................................3-7
Fuses, replacing ....................................6-32

H

Handlebar switches .................................3-5
Headlight bulb, replacing.......................6-34
Helmet holder........................................3-10
High beam indicator light.........................3-2
Horn switch .............................................3-6

I

Identification numbers .............................9-1
Ignition circuit cut-off system .................3-14
Indicator and warning lights ....................3-2

K

Key identification number........................9-1

L

Labels, location of ...................................1-5
License plate light bulb, replacing .........6-36

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 ..............................................9-2

N

Neutral indicator light ..............................3-2
Noise regulation ......................................9-4

P

Parking ....................................................5-4
Part locations ..........................................2-1
Pre-operation check list...........................4-2

R

Rear brake light switch, adjusting .........6-22

Rear suspension, lubricating ................ 6-29
Rider seat ............................................... 3-9

S

Safety defects, reporting......................... 9-3
Safety information ................................... 1-1
Shifting.................................................... 5-2
Shift pedal ............................................... 3-6
Shock absorber assembly, adjusting .... 3-11
Sidestand.............................................. 3-13
Sidestand, checking and lubricating ..... 6-28
Spark plugs, checking............................. 6-8
Specifications.......................................... 8-1
Speedometer .......................................... 3-3
Starting and warming up a cold 

engine................................................... 5-1

Start switch ............................................. 3-6
Steering, checking ................................ 6-30
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-37
Swingarm pivots, lubricating ................. 6-29

T

Tachometer unit ...................................... 3-3
Tail/brake light ...................................... 6-35
Throttle cable free play, adjusting ......... 6-16
Throttle grip and cable, checking and 

lubricating ........................................... 6-27

Tires...................................................... 6-17
Tool kit .................................................... 6-1
Transfer case oil ................................... 6-12
Troubleshooting .................................... 6-37
Troubleshooting chart ........................... 6-38
Turn signal indicator lights ...................... 3-2
Turn signal light bulb, replacing ............ 6-35
Turn signal switch ................................... 3-5

U5PX13E0.book  Page 1  Monday, May 10, 2004  9:26 AM

Summary of Contents for WARRIOR XV17PCT

Page 1: ...5PX 28199 13 LIT 11626 18 23 XV17PCT XV17PCTC OWNER S MANUAL ...

Page 2: ...EAU10041 U5PX13E0 book Page 1 Monday May 10 2004 9 26 AM ...

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

Page 4: ...e consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow ...

Page 5: ...RAINED 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 RELIABILITY OF THIS MOTORCYCLE U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

Page 6: ... Corporation U S A 1st edition May 2004 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 18 23 AFFIX DEALER LABEL HERE U5PX13E0 book Page 3 Monday May 10 2004 9 26 AM ...

Page 7: ...ark plugs 6 8 Canister for California only 6 9 Engine oil and oil filter cartridge 6 9 Transfer case oil 6 12 Replacing the air filter elements 6 13 Adjusting the throttle cable free play 6 16 Adjusting the valve clearance 6 17 Tires 6 17 Cast wheels 6 19 Accessories and replacement parts 6 20 Adjusting the clutch lever free play 6 20 Adjusting the brake lever free play 6 21 Adjusting the rear bra...

Page 8: ... AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

Page 9: ...cidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where ot...

Page 10: ... shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine o...

Page 11: ... under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle...

Page 12: ...cle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5PX13E0 book Page 5 Monday May 10 2004 9 26 AM ...

Page 14: ...SAFETY INFORMATION 1 6 1 2 4 California only 1 3 5 California only U5PX13E0 book Page 6 Monday May 10 2004 9 26 AM ...

Page 15: ...410 Left view 1 Engine oil drain bolt crankcase page 6 9 2 Shift pedal page 3 6 3 Fuel tank cap page 3 7 4 Helmet holder page 3 10 5 Fuses page 6 32 6 Owner s tool kit page 6 1 U5PX13E0 book Page 1 Monday May 10 2004 9 26 AM ...

Page 16: ...nt fork spring preload adjusting bolt page 3 10 5 Engine oil filter cartridge page 6 9 6 Brake pedal page 3 7 7 Engine oil drain bolt oil tank page 6 9 8 Shock absorber assembly spring preload adjusting nut page 3 11 9 Shock absorber assembly rebound damping force adjusting knob page 3 11 U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

Page 17: ...er page 3 6 2 Left handlebar switches page 3 5 3 Speedometer page 3 3 4 Tachometer unit page 3 3 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 5 7 Throttle grip page 6 16 8 Brake lever page 3 7 U5PX13E0 book Page 3 Monday May 10 2004 9 26 AM ...

Page 18: ... EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF ...

Page 19: ... the electrical cir cuit NOTE This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit is defective the following cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11480 Engine trou...

Page 20: ...he electrical circuit The tachometer unit is equipped with the following an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the fuel level warning light came on a meter lighting control a clock a self diagnosis device NOTE Be sure to turn the key to ON...

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

Page 22: ...0 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the vehicle has traveled both about 150 m 490 ft and for approximately 15 seconds However the turn signal lights can also b...

Page 23: ... Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 14 EAU12870 Shift pedal The ...

Page 24: ...13070 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock ...

Page 25: ...0070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13360 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line ...

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

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

Page 28: ...reload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in direction b NOTE Use the special wrench included in the owner s tool kit to make the ad justment The spring preload setting is deter mined by measuring distance A shown in the illustration The long er distance A is the lower the...

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

Page 30: ...ile holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand ...

Page 31: ... the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have...

Page 32: ...ter the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle ...

Page 33: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not...

Page 34: ...ver free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary ...

Page 35: ...hat operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and swit...

Page 36: ...ansmission is in gear with the clutch lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 14 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11560 The fuel level warning light and en gine trouble...

Page 37: ...TION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train w...

Page 38: ...dicator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not pu...

Page 39: ...oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may ...

Page 40: ...ELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR S...

Page 41: ...WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

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

Page 43: ... Clutch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam ag...

Page 44: ...ke and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leak age Rep...

Page 45: ...filter car tridge Replace 22 Transfer case oil Check for leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle...

Page 46: ...frequently when riding 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...

Page 47: ...ne could be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark...

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

Page 49: ...ely tightened otherwise oil may seep out when the engine is run ning To change the engine oil with or without oil filter cartridge replace ment 1 Remove the rider seat See page 3 9 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the oil tank to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank 5...

Page 50: ...n oil filter wrench and then tighten it to the specified torque with a torque wrench 10 Install the engine oil drain bolts and then tighten them to the spec ified torque 11 Pour only 2 5 L 2 6 US qt 2 2 Imp qt of the specified amount of recommended engine oil through the filler hole insert the dipstick and then tighten the oil filler cap 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Oil fi...

Page 51: ...Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 16 Turn the engine off and then check the oil level and correct it if necessary 17 Install the rider seat EAU20051 Transfer case oil The transfer case must be checked for oil leakage before each ride If any leakage is found have a Ya...

Page 52: ...ication chart Replace the air filter elements more frequently if you are riding in un usually wet or dusty areas Air filter case element To replace the air filter element 1 Remove the rider seat See page 3 9 2 Remove the air induction system cover by removing the bolts 3 Remove the fuel tank as follows a Disconnect fuel hose A from the joint as shown b Remove the nuts c Disconnect fuel hose B from...

Page 53: ...disconnect ed d Remove the hoses as shown and then remove the fuel tank by pulling it upward e Remove the foam damper 4 Remove the air filter case bolts 5 Loosen the air filter joint clamp screw and then pull off the air filter case 6 Remove the air filter case cover by removing the screws 7 Remove the air filter element by removing the screws 1 Hose 1 Foam damper 1 Air filter case 2 Bolt 1 Air fi...

Page 54: ...e cover by in stalling the screws 14 Install the air filter case by pushing it onto the air filter joint and then tightening the air filter joint clamp screw 15 Install the air filter case by install ing the bolts 16 Install the fuel tank as follows a Install the foam damper b Place the fuel tank in the origi nal position and then connect fuel hose B and the hoses shown WARNING EWA10420 Before ins...

Page 55: ...er ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 5 Install the silencer case air filter cover by installing the screws 6 Install the fuel tank See steps 16 17 under Air filter case ele ment EAU21380 Adjusting the throttle cable free play The throt...

Page 56: ...uals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift ...

Page 57: ...laced WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with cast wheels an...

Page 58: ...the operating conditions EAU21960 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle 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...

Page 59: ...cement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as s...

Page 60: ...ut in direction b 6 Tighten the locknut at the clutch le ver and the crankcase EAU22092 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di recti...

Page 61: ...ect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the inte...

Page 62: ...ing thickness is less than 0 8 mm 0 03 in have a Yamaha dealer replace the brake pads as a set 3 Install the brake caliper bolt and then tighten it to the specified torque EAU22580 Checking the brake fluid level Front brake Rear brake Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective 1 Brake caliper bolt 1 Lining thickness Tightening torque...

Page 63: ...t 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 deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly ...

Page 64: ...e belt with a force of 45 N 4 5 kgf 10 lbf applied to the belt with a belt ten sion gauge as shown NOTE A belt tension gauge is available at a Yamaha dealer 4 Calculate the drive belt slack by subtracting the measurement not ed in step 2 from the measurement noted in step 3 5 If the drive belt slack is incorrect adjust it as follows EAU23080 To adjust the drive belt slack 1 Loosen the axle nut and...

Page 65: ...090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should 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 WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause inter...

Page 66: ...ould be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U5PX13E0 book Page 27 Monday May 10 2004 9 2...

Page 67: ...g 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 WARNING EWA10730 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 pur pose grease Recommended lubricant Lithium s...

Page 68: ...t be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle 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 vehicle on a level sur face and hold it in an upright posi tion 2 While applyin...

Page 69: ...ng must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle 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 Ya...

Page 70: ...ny 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 attention Batteries produce explosive hy drogen gas Therefore keep sp...

Page 71: ...charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your battery EAU34330 Replacing the fuses The main fuse and the fuse box which contai...

Page 72: ...check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Electronic fuel injection fuse 5 Backup fuse for odometer and clock 6 Auto decompression fuse 7 Spare fuse 8 ECU fuse Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Igniti...

Page 73: ...keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoro...

Page 74: ...U24180 Tail brake light This model is equipped with an LED type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU24210 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 1 Do not touch the glass part of the bulb 1 Screw U5PX13E0 book Page ...

Page 75: ...oving the nuts washers and rubber dampers 2 Remove the license plate light lens by removing the nuts and washers 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the license plate light lens by installing the washers and the nuts 6 Install the license plate light unit by installing the rubber dampers washers and the nuts 1 Turn signal light bulb 1 Nut 2 ...

Page 76: ...sing a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for examp...

Page 77: ...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 78: ... do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plast...

Page 79: ... cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel...

Page 80: ...cycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 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...

Page 81: ...very month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 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 information on storing the bat...

Page 82: ...ement 4 10 L 4 33 US qt 3 61 Imp qt Transfer gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 40 L 0 42 US qt 0 35 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Electronic fuel injection Manufacturer NIPPON INJECTOR Model INP 732 ...

Page 83: ...psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 18M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber ...

Page 84: ... indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A ECU fuse 10 0 A Electronic fuel injection fuse 15 0 A Backup fuse 7 5 A Auto decompression fuse 15 0 A U5PX13E0 book Page 3 Monday May 10 2004 9 26 AM ...

Page 85: ...entification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and...

Page 86: ...bel is affixed to the frame under the rider seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

Page 87: ...estigation 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 Tr...

Page 88: ...hicle 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 ...

Page 89: ...eminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 k...

Page 90: ...FORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5PX13E0 book Page 6 Monday May 10 2004 9 26 AM ...

Page 91: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5PX13E0 book Page 7 Monday May 10 2004 9 26 AM ...

Page 92: ...CONSUMER INFORMATION 9 8 9 U5PX13E0 book Page 8 Monday May 10 2004 9 26 AM ...

Page 93: ...ed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing...

Page 94: ...cked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U5PX13E0 book Page 10 Monday May 10 2004 9 26 AM ...

Page 95: ...cation number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 36 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 9 2 N Neutral indicator light 3 2 Noise regulation 9 4 P Parking 5 4 Part locations 2 1 Pre operation check list 4 2 R Rear brake light switch a...

Page 96: ...DEX V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheels 6 19 U5PX13E0 book Page 2 Monday May 10 2004 9 26 AM ...

Page 97: ...PRINTED IN JAPAN 2004 05 0 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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