Yamaha Wild Star XV1600A Owner'S Manual Download Page 45

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PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-3

Removing and installing the panel .......................6-6

Checking the spark plugs ....................................6-7

Engine oil and oil filter cartridge ..........................6-8

Transfer case oil .................................................6-12

Cleaning the air filter element ............................6-13

Adjusting the carburetor .....................................6-16

Adjusting the engine idling speed ......................6-16

Adjusting the throttle cable free play ..................6-17

Adjusting the valve clearance ............................6-17

Tires ...................................................................6-17

Spoke wheels ....................................................6-20

Adjusting the clutch lever free play ....................6-21

Adjusting the brake lever free play .....................6-22

Adjusting the brake pedal position .....................6-22

Adjusting the rear brake light switch ..................6-23

Checking the front and rear brake pads .............6-23

Checking the brake fluid level ............................ 6-25

Changing the brake fluid ................................... 6-26

Drive belt slack .................................................. 6-26

Checking and lubricating the brake and

shift pedals ...................................................... 6-28

Checking and lubricating the brake and

clutch levers .................................................... 6-29

Checking and lubricating the sidestand ............ 6-30

Checking the front fork ...................................... 6-30

Checking the steering ....................................... 6-31

Checking the wheel bearings ............................ 6-31

Battery ............................................................... 6-32

Replacing the fuses .......................................... 6-33

Replacing the headlight bulb ............................. 6-35

Replacing a turn signal light bulb or the tail/

brake light bulb ................................................ 6-37

Troubleshooting ................................................. 6-37

Troubleshooting chart ........................................ 6-38

E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM

Summary of Contents for Wild Star XV1600A

Page 1: ...XV1600A OWNER S MANUAL ...

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

Page 3: ...of your Yamaha Wild Star s 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 Yamaha dealer The Yamaha...

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 informatio...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 6: ...NUAL 2000 by Yamaha Motor Co Ltd 1st Edition July 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_5JA book Page 3 Wednesday September 13 2000 6 06 PM ...

Page 7: ...RUMENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 8: ...E_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

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

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 12: ... Starter choke knob page 3 12 3 Fuel cock page 3 11 4 Rider seat page 3 12 5 Owner s tool kit page 6 1 6 Helmet holder page 3 13 7 Rear turn signal lights page 6 37 8 Tail brake light page 6 37 9 Fuses page 6 33 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 13: ...9 13 Fuel tank cap page 3 9 14 Headlight page 6 35 15 Front turn signal lights page 6 37 16 Throttle stop screw page 6 16 17 Brake pedal page 3 8 18 Rider footrest 19 Rear shock absorber spring preload adjusting nut page 3 14 20 Muffler E_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 14: ...lever page 3 7 2 Left handlebar switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 6 6 Throttle grip page 6 17 7 Brake lever page 3 8 E_5JA book Page 3 Wednesday September 13 2000 6 06 PM ...

Page 15: ...dlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose 3 10 Fuel cock 3 11 Starter choke knob 3 12 Locking the steering with a padlock 3 12 Rider seat 3 12 Helmet holder 3 13 Adjusting the shock absorber assembly 3 14 Sidestand 3 15 Ignition circuit cut off system 3 16 E_5JA book Page 1 Wednesday September 13 2000 6 0...

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

Page 17: ... fuel as soon as possible EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU00057 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU00091 Engine troub...

Page 18: ...following order CB 27E To reset a tripmeter select it by push ing the mode button left and then hold down the set button right for at least one second The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE This motorcycle is not equipped with a tachometer however it has a built in engine spee...

Page 19: ... agnosis device for various electrical circuits If any of those circuits are defective the engine trouble warning light will come on or the fuel level warning light will flash If this occurs have a Yamaha dealer check the motorcycle ECA00061 CAUTION To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this occurs EAU00109 Anti theft alarm optional This motorcycle can ...

Page 20: ...e hours and min utes flash 3 Push the left button and only the hour display will flash 4 Push the right button to change the hours 5 Push the left button and only the minute display will flash 6 Push the right button to change the minutes 7 Push the left button and both the hours and minutes will flash 8 Push the right button for two sec onds to set the clock 1 Clock 2 Set button 3 Mode button E_5...

Page 21: ...nal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU00138 Engine stop switch Set this switch to to stop the en gine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck EAU00134 Light switch Set this switch to to turn on the auxiliary light meter lighting and tail light ...

Page 22: ...lowly 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 16 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 the clutch lever when shifting the gears of the 5 speed con stant mesh transmis...

Page 23: ...ght handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Brake pedal E_5JA book Page 8 Wednesday September 13 2000 6 06 PM ...

Page 24: ...ver NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked EW000024 WARNING Make sure that the fuel tank cap is properly installed before riding EAU01183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion EW0...

Page 25: ...e EAU02955 Fuel tank breather hose Before operating the motorcycle Check the fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary Recommended fuel Regular unleaded gasoline with a research octane number of 91 or higher Fuel tank capacity Tota...

Page 26: ... the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling 1 Pointed end positioned over OFF OFF closed position 1 Pointed end positioned over ON ON normal posit...

Page 27: ... 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 until the holes in the two brackets are aligned and then lock the steering with a suitable padlock EAU01737 Rider seat To remove the rider seat 1 Insert the key into the main switch and then turn it counterclockwise to OPE...

Page 28: ...under the rider seat To secure a helmet to the helmet holder 1 Remove the rider seat See page 3 12 for rider seat removal and in stallation procedures 2 Attach the helmet to the helmet holder and then securely install the seat EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident To release the helm...

Page 29: ...en the suspen sion turn the adjusting nut in di rection a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b NOTE The spring preload setting is de termined by measuring distance A shown in the illustration The longer distance A is the higher the spring preload the shorter dis tance A is the lower the spring preload Use the special wrench included...

Page 30: ...ber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the mo...

Page 31: ...if it does not function properly EAU00331 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is p...

Page 32: ... clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should...

Page 33: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 34: ...specified level Check vehicle for oil leakage 6 8 6 11 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 26 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic...

Page 35: ...ires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 20 6 31 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 6 29 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if ...

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Page 37: ...5 Starting the engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 5 Parking 5 6 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 38: ... 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 EAU03515 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 39: ...ne 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 should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00055 CAUTION For maximum engine life always warm the eng...

Page 40: ...n press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 41: ...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 Shift up swiftly and avoid high en gine speeds during acceleration Do not rev the engine while shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of...

Page 42: ...his period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU01740 0 1 000 km Avoid prolonged operation above 1 3 throttle 1 000 1 600 km Avoid prolonged operation above 1 2 throttle ECA00026 CAUTION After 1 000 km of operation the en gine oil and transfer case oil must be changed and the oil filter car tridge replaced 1 600 km and beyon...

Page 43: ...ch 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_5JA book Page 6 Wednesday September 13 2000 6 06 PM ...

Page 44: ...E_5JA book Page 7 Wednesday September 13 2000 6 06 PM ...

Page 45: ... free play 6 22 Adjusting the brake pedal position 6 22 Adjusting the rear brake light switch 6 23 Checking the front and rear brake pads 6 23 Checking the brake fluid level 6 25 Changing the brake fluid 6 26 Drive belt slack 6 26 Checking and lubricating the brake and shift pedals 6 28 Checking and lubricating the brake and clutch levers 6 29 Checking and lubricating the sidestand 6 30 Checking t...

Page 46: ... 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 EAU03394 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 12 for rider seat removal and installation proce dures The service information included in this manual a...

Page 47: ...ired 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 un safe for use Consult a Yamaha dealer before attempting any chang es E_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 48: ...E JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 20 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on pa...

Page 49: ...m 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check operation and shock absorb...

Page 50: ...nder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 23 Engine oil Change 24 Engine oil filter cartridge Replace 25 Transfer case oil Check oil level Change 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE J...

Page 51: ...ance jobs described in this chapter Refer to this section each time the pan el needs to be removed and installed EAU00491 Panel A To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 1 Bolt E_5JA book Page 6 Wednesday September 13 2000 6 06 PM ...

Page 52: ...r 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 surface...

Page 53: ...n upright position NOTE Make sure that the motorcycle is posi tioned 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 12 for rider seat removal and in stallation procedures 3 Start the engine warm it up until the engine oil has reached a nor mal temperature of 60 C let it continue to idle for ten seconds and then tur...

Page 54: ...he oil level rises faster starting from the half level portion on the dipstick 6 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 7 Install the rider seat ECA00027 CAUTION Make sure that the oil filler cap is se curely tightened otherwise oil may seep out when the engine is running 1 Engine oil filler cap 1 Maximum level 2 Minimum level 3 Dipstick E_5JA book Page 9 ...

Page 55: ...orrect the used oil 5 Remove the engine oil drain bolt to drain the oil from the crankcase 6 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 7 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 8 Install the new oil filter cartridge and then tighten it t...

Page 56: ...tes the clutch do not mix any chemical additives with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 13 Install the engine oil filler cap 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engin...

Page 57: ...check hole 3 If the oil is below the brim of the check hole remove the oil filler cap add sufficient oil of the rec ommended type to raise it to the correct level and then install the oil filler cap 4 Install the oil check bolt and then tighten it to the specified torque To change the transfer case oil 1 Place an oil pan under the transfer case to collect the used oil 2 Remove the drain bolt and t...

Page 58: ...r oil leakage If oil is leaking immediately turn the engine off and check for the cause EAU03707 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case bolts 1 Transfer case oil ch...

Page 59: ...se out 3 Remove the air filter case cover by removing the screws 4 Disconnect the hoses shown 5 Remove the air filter element by removing the screws and then disconnect the hose shown 1 Air filter joint clamp screw 1 Screw 2 2 Hose 2 3 Air filter case cover 1 Screw 2 2 Hose E_5JA book Page 14 Wednesday September 13 2000 6 06 PM ...

Page 60: ...er element by in serting it into the air filter case then installing the screws and then connect the hose shown 8 Install the air filter case cover by installing the screws 9 Connect the hoses shown 10 Install the air filter case by pushing it onto the air filter joint and then tighten the air filter joint clamp screw 11 Install the air filter case by install ing the bolts 1 Screw 2 2 Hose 1 Hose ...

Page 61: ...ed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 4 400 r min NOTE The engine is warm when i...

Page 62: ...g 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 EAU01848 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 pres...

Page 63: ...ay re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspens...

Page 64: ...eplacement 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 tube tires EW000078 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...

Page 65: ...aximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must b...

Page 66: ...ever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the a...

Page 67: ...orking properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU01746 Adjusting the brake pedal position The top ...

Page 68: ...vated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear 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 EAU00721 ...

Page 69: ...ve a Yamaha dealer replace the brake pads as a set EAU01198 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad for wear without having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost dis appeared have a Yamaha dealer r...

Page 70: ...mended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may resul...

Page 71: ...ve belt slack should be checked before each ride and adjusted if neces sary To check the drive belt slack 1 Place the motorcycle on a level surface and hold it in an upright position 2 Note the current position of the drive belt using the marks near the check hole NOTE The marks near the drive belt check hole are 5 mm apart 3 Note the position of the drive belt with a force of 45 N 4 5 kg ap plied...

Page 72: ... EAU01748 To adjust the drive belt slack 1 Loosen the rear wheel axle nut and the brake caliper bracket bolt 2 Loosen the drive belt puller lock nut on each side of the swingarm Drive belt slack 7 5 13 mm 1 Wheel axle nut 1 Brake caliper bracket bolt E_5JA book Page 27 Wednesday September 13 2000 6 06 PM ...

Page 73: ...the engine Keep the drive belt slack within the specified range 5 Tighten the axle nut and the brake caliper bracket bolt to the specified torques EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary 1 Drive belt slack adjusting bolt 2 2 Drive belt puller l...

Page 74: ...e brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease E_5JA book Page 29 Wednesday September 13 2000 6 06 PM ...

Page 75: ... main tenance and lubrication chart To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several ti...

Page 76: ...upport the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart ...

Page 77: ...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 sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclos...

Page 78: ... 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 Yamaha d...

Page 79: ...trical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Signaling system fuse 2 Ignition fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Odometer fuse 6 Spare fuse 3 1 Main fuse 2 Spare main fuse Specified fuses Main fuse 30 A Ignit...

Page 80: ...ns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the headlight unit and bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Screw 2 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder E_5JA book Page 35 Wednesday September 13 2000 6 06 PM ...

Page 81: ...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 Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamah...

Page 82: ...ore 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 chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have...

Page 83: ...tion 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 qui...

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Page 85: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 86: ... electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets the drive belt and wheel axles Always rinse the dirt and degreaser off with wa ter Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especial...

Page 87: ...s and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after w...

Page 88: ... 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 plat ed surfaces 4 Use spray oil as a universal cl...

Page 89: ...cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel co...

Page 90: ...e to ground the spark plug electrodes while turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires ...

Page 91: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 92: ...r Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement 3 7 L With oil filter cartridge replacement 4 1 L Total amount dry engine 5 0 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti friction mo...

Page 93: ...ransmission Primary reduction system Spur gear Primary reduction ratio 1 532 Secondary reduction system Belt Secondary reduction ratio 2 320 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 438 2nd 1 579 3rd 1 160 4th 0 906 5th 0 750 Chassis Frame type Double cradle Caster angle 32 Trail 142 mm Tire Front Type Tube tire Size 130 90 16 67H Manufacturer model Dunlop D404F...

Page 94: ... Size 16 MT 3 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 140 mm Rear 110 mm Electrical Ignition system Transistorized coil ignition digital Chargin...

Page 95: ... V 4 W 1 Meter lighting 14 V 0 6 W 4 Neutral indicator light 12 V 1 W 1 High beam indicator light 12 V 1 W 1 Turn indicator light 12 V 1 W 1 Fuel level warning light LED 1 Engine trouble warning light LED 1 Fuses Main fuse 30 A Ignition fuse 15 A Signaling system fuse 10 A Headlight fuse 15 A Carburetor heater fuse 10 A Odometer fuse 5 A E_5JA book Page 4 Wednesday September 13 2000 6 06 PM ...

Page 96: ...ric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55 9...

Page 97: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_5JA book Page 1 Wednesday September 13 2000 6 06 PM ...

Page 98: ... EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify you...

Page 99: ...der the rider seat See page 3 12 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_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 100: ...ducing 5 4 Fuel gauge 3 4 Fuel level warning light 3 2 Fuel tank breather hose 3 10 Fuel tank cap 3 9 Fuses replacing 6 33 H Handlebar switches 3 6 Headlight bulb replacing 6 35 Helmet holder 3 13 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Idling speed adjusting 6 16 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 ...

Page 101: ... play adjusting 6 17 Tires 6 17 Tool kit 6 1 Transfer case oil 6 12 Troubleshooting 6 37 Troubleshooting chart 6 38 Turn signal indicator light 3 2 Turn signal light or tail brake light bulb replacing 6 37 Turn signal switch 3 6 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheels 6 20 E_5JA book Page 2 Wednesday September 13 2000 6 06 PM ...

Page 102: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 103: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 104: ......

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