Yamaha XJR1300 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

6

EW000109

WARNING

_

A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have 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.

_

EAU01756

Rear brake light switch
adjustment

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.

1. Remove panel A. (See page 6-5

for panel removal and installation
procedures.)

2. Turn the adjusting nut while hold-

ing 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

.

3. Install the panel.

1. Rear brake light switch
2. Rear brake light switch adjusting nut

E_5ea.book Page 18 Tuesday, October 2, 2001 3:54 PM

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Summary of Contents for XJR1300

Page 1: ...5EA 28199 E4 XJR1300 OWNER S MANUAL ...

Page 2: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 3: ... to enjoy all advantages of your XJR1300 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha de...

Page 4: ...be 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 informa...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING _ PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE _ E_5ea book Page 2 Tuesday October 2 2001 3 54 PM ...

Page 6: ...MANUAL 2001 by Yamaha Motor Co Ltd 1st edition July 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5ea book Page 3 Tuesday October 2 2001 3 54 PM ...

Page 7: ...MENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 8: ...E_5ea book Page 2 Tuesday October 2 2001 3 54 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

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

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 12: ...orber assembly spring preload adjusting rings page 3 15 4 Luggage strap holders page 3 16 5 Helmet holder seat lock page 3 12 page 3 11 6 Throttle stop screw page 6 13 7 Shift pedal page 3 6 8 Engine oil filler element page 6 8 9 Engine oil drain bolt page 6 8 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 13: ...ge 6 1 14 Rear brake fluid reservoir page 6 19 15 Fuses page 6 29 16 Air filter element page 6 11 17 Fuel tank page 3 8 18 Front brake fluid reservoir page 6 19 19 Front fork spring preload adjusting bolt page 3 14 20 Headlight page 6 29 21 Engine oil filler cap page 6 8 22 Engine oil level check window page 6 8 23 Brake pedal page 3 7 E_5ea book Page 2 Tuesday October 2 2001 3 54 PM ...

Page 14: ...ches page 3 4 3 Starter choke lever page 3 11 4 Speedometer unit page 3 3 5 Fuel gauge page 3 3 6 Tachometer page 3 3 7 Right handlebar switches page 3 5 8 Brake lever page 3 7 9 Throttle grip page 6 13 10 Main switch steering lock page 3 1 E_5ea book Page 3 Tuesday October 2 2001 3 54 PM ...

Page 15: ...lever 3 5 Shift pedal 3 6 Brake lever 3 7 Brake pedal 3 7 Fuel tank cap 3 8 Fuel 3 9 Fuel tank breather hose 3 10 Fuel cock 3 10 Starter choke lever 3 11 Seat 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assemblies 3 15 Luggage strap holders 3 16 Sidestand 3 17 Ignition circuit cut off system 3 17 E_5ea book Page 1 Tuesday October 2 20...

Page 16: ...trical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left or right 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 into the main switch and then turn it to OFF while still pushing it EW000016 WARNING _ Never turn the key to OFF or LOCK while the moto...

Page 17: ... light This indicator light comes on when the transmission is in the neutral position EAU03201 Oil level warning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clut...

Page 18: ...01 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003 CAUTION _ Do not operate the engine in the ta chometer red zone Red zone 9 500 r min and above _ EAU00110 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E ap...

Page 19: ...ghts The hazard light is used in case of an emergency or to warn other drivers when your motorcycle is stopped where it might be a traffic hazard EC000006 CAUTION _ Do not use the hazard light for an ex tended length of time otherwise the battery may discharge _ EAU03889 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released ...

Page 20: ... also Set the switch to to turn off all the lights EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION _ See page 5 1 for starting instruc tions prior to starting the engine _ EAU00153 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 T...

Page 21: ...he arrow mark on the clutch lever The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 17 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmis...

Page 22: ...e lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Arrow mark 2 Brake lever pos...

Page 23: ... fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE _ The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNING _ Make sure that the fuel tank cap is properly closed before rid...

Page 24: ...CA00104 CAUTION _ Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded f...

Page 25: ...ver in this position fuel flows to the carburetors when the engine is running Turn the fuel cock le ver to this position when starting the engine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Quickly turn the fuel cock lever to this position if you run out of fuel while riding otherwise the engine may stall and will have to be p...

Page 26: ... the le ver to ON or RES if you have not refueled yet EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU04406 Seat To remove the seat 1 Insert the key into the seat lock and then turn it as shown 2 Pull...

Page 27: ...ed before riding _ EAU04291 Helmet holder To open the helmet holder insert the key into the seat lock and then turn the key as shown To lock the helmet holder turn the key to the original position and then re move it 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 _ 1 Projection 2 Seat holde...

Page 28: ...ng them When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the motorcycle be careful not to let any water enter the storage compartment EAU00285 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts EW000035 WARNING _ Always adjust both fork legs equal ly ...

Page 29: ... decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE _ Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt _ CI 10E 1 Spring preload adjusting bolt 1 Current setting 2 Front fork cap bolt Setting Minimum soft 7 Standard 5 Maximum hard 1 E_5ea book Page 14 Tuesday October 2 2001 3 54...

Page 30: ... as follows using the special wrenches included along with the owner s tool kit To increase the spring preload and thereby harden the suspension hold the upper ring in place while turning the lower ring adjusting ring on each shock absorber assembly as shown in illustration To decrease the spring preload and thereby soften the suspension hold the upper ring in place while turning the lower ring ad...

Page 31: ... Do not tamper with or attempt to open the gas cylinders Do not subject the shock ab sorbers to an open flame or oth er high heat sources otherwise they may explode due to exces sive gas pressure Do not deform or damage the gas cylinders in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorbers _ EAU04276 Luggage strap holders There are fou...

Page 32: ...em has been designed to assist the operator in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly _ EAU03741 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has th...

Page 33: ...ONS 3 18 3 EW000046 WARNING _ The vehicle must be placed on the centerstand during this in spection If a malfunction is noted have a Yamaha dealer check the sys tem before riding _ E_5ea book Page 18 Tuesday October 2 2001 3 54 PM ...

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

Page 35: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 36: ... 7 6 8 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 19 6 20 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specifi...

Page 37: ...nd tread depth Check air pressure Correct if necessary 6 14 6 17 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 Chassis fasteners Make sur...

Page 38: ...E_5ea book Page 3 Tuesday October 2 2001 3 54 PM ...

Page 39: ... 5 Starting a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 40: ...s in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down _ 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set ...

Page 41: ...g the start switch or if it does not go off after starting with sufficient engine oil have a Yamaha dealer check the electrical circuit _ 6 After starting the engine move the starter choke lever back halfway ECA00045 CAUTION _ For maximum engine life never ac celerate hard when the engine is cold _ 7 When the engine is warm turn the starter choke off NOTE _ The engine is warm when it responds norm...

Page 42: ...he 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 dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02941 Recommended shift points for Switzerland only The recommended sh...

Page 43: ...his rea son you should read the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU03749 0 1 000 km Avoid p...

Page 44: ...he key from the main switch 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_5ea book Page 5 Tuesday October 2 2001 3 54 PM ...

Page 45: ... and clutch fluid levels 6 19 Changing the brake and clutch fluids 6 21 Drive chain slack 6 21 Lubricating the drive chain 6 23 Checking and lubricating the cables 6 23 Checking and lubricating the throttle grip and cable 6 24 Checking and lubricating the brake and shift pedals 6 24 Checking and lubricating the brake and clutch levers 6 24 Checking and lubricating the centerstand and sidestand 6 2...

Page 46: ...tor cycle maintenance work have a Yamaha dealer do it for you _ EAU03758 Owner s tool kit The owner s tool kit is located under the seat See page 3 11 for seat re moval and installation procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additiona...

Page 47: ...ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses and vacuum hose 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 fluid level and vehicle for fluid leakage See NOTE on page 6 4 7 Front brake Check operation fluid level and ...

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

Page 49: ...e master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged _ 23 Engine oil filter element Replace 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Lights signals and switches Check operation Adjust headlight beam NO ITEM CH...

Page 50: ...this section each time the pan el needs to be removed and installed EAU01691 Panel A To remove the panel 1 Remove the seat See page 3 11 for seat removal and installation procedures 2 Remove the screw and then take the panel off To install the panel 1 Place the panel in the original po sition and then install the screw 2 Install the seat 1 Panel A 1 Screw E_5ea book Page 5 Tuesday October 2 2001 3...

Page 51: ...in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medi um to light tan the ideal color when the motorcycle is ridden nor mally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to di...

Page 52: ... be tightened to the speci fied torque as soon as possible _ 4 Install the spark plug cap EAU04409 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the motorcycle on the ...

Page 53: ...1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE _ Skip steps 4 8 if the oil filter element is not being replaced _ 4 Remove the oil filter element drain screw to drain the oil from the oil filter element 5 Remove the oil filte...

Page 54: ...il filter element drain screw and then tighten it to the specified torque 9 Install the engine oil drain bolt and then tighten it to the specified torque 10 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filter element 2 O ring 2 1 Projection 2 Slot Tightening torque Oil filter element cover bolt 15 Nm 1 5 m kgf Tightening torque Oil fi...

Page 55: ...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 _ 12 Turn the engine off and then check the oil leve...

Page 56: ...al and installation procedures 2 Remove panel A See page 6 5 for panel removal and installation procedures 3 Remove the air filter case cover by removing the screws 4 Pull the air filter element out 5 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 6 Insert the a...

Page 57: ...tors 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 rience The adjustment described in the following section however may be serviced by the owner as part of routine maintenance EC000095 CAUTION _ The carburetors have been set ...

Page 58: ...f 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 specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment _ EAU00635 Adjusting the throttle cable free play The throttle cable free p...

Page 59: ...ary adjusted before each ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model _ CE 01E CE 07E Tire air pressure measured on cold...

Page 60: ... during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the suspension and tire air pressure with regard to the load Check the tire condition and air pressure before each ride _ Tire 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...

Page 61: ...teristics 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 installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride _ CE 10E CE 14E 1 Tire air valve 2 Tire air val...

Page 62: ... note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalan...

Page 63: ... rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Remove panel A See page 6 5 for panel removal and installation procedures 2 Turn the adjusting nut while hold ing the rear brake light switch in place To make the brake light come on earlier turn ...

Page 64: ...e has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04169 Checking the brake and clutch fluid levels Insufficient brake fluid may allow air to enter the brake or clutch systems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brak...

Page 65: ...agm will lose its shape from the negative pressure if the fluid level goes down too far Be sure to return the diaphragm to its original shape before installing it into the brake or clutch fluid reservoir Be careful that water does not en ter the brake or clutch fluid reser voir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may...

Page 66: ...e damaged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU00745 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest po...

Page 67: ...ks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment _ EC000096 CAUTION _ Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits _ 3 Tighten the locknuts and th...

Page 68: ... 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION _ Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings _ EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride...

Page 69: ...ke and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease...

Page 70: ... down smoothly have a Yamaha dealer check or re pair it _ EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic 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 ...

Page 71: ... EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering 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 EW000115 WARNING _ Securely support the motorcycle so that there is no danger of it falling over _ 2...

Page 72: ...ttery cell seals as this would permanent ly damage the battery _ EW000116 WARNING _ Electrolyte is poisonous and dangerous 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...

Page 73: ...lace 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the 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 charg...

Page 74: ... 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 EAU04189 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving ...

Page 75: ...00105 CAUTION _ 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 Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the headlight bulb cover and then connect the coupler 6 Install the...

Page 76: ...t stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the seat EAU03497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 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 installing th...

Page 77: ... by removing the bolts 3 Remove the brake calipers by re moving the bolts ECA00047 CAUTION _ Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut _ 4 Loosen the front wheel axle pinch bolt then the wheel axle 5 Place the motorcycle on the cen terstand 6 Pull the wheel axle out and then remove the wheel 1 Speedometer cable 1 Bolt 3 2 Brak...

Page 78: ... the brake pads before install ing the brake calipers onto the brake discs _ 5 Install the brake hose holders by installing the bolts 6 Take the motorcycle off the cen terstand so that the front wheel is on the ground 7 Tighten the wheel axle then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 8 Connect the speedometer cable 9 Push down hard on the handlebar s...

Page 79: ... on the cen terstand 4 Remove the axle nut and the brake caliper by removing the bolts ECA00082 CAUTION _ Do not apply the brake after the brake caliper has been removed otherwise the brake pads will be forced shut _ 5 Loosen the locknuts and then turn the drive chain slack adjusting bolt on each side of the swingarm fully in direction a 6 Push the wheel forward and then remove the drive chain fro...

Page 80: ... onto the rear sprocket and then adjust the drive chain slack See page 6 22 for drive chain slack adjustment pro cedures 4 Connect the brake torque rod to the brake caliper bracket by in stalling the bolt and the nut 5 Install the brake caliper by install ing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc _ 6 Ta...

Page 81: ... troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infe...

Page 82: ...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 The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over...

Page 83: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 84: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners...

Page 85: ...eld is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding i...

Page 86: ... damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test its ...

Page 87: ...p Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps on...

Page 88: ...very 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 0 C or more than 30 C For more information on storing the battery se...

Page 89: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 90: ... 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 3 0 L With oil filter element replacement 3 35 L Total amount dry engine 4 2 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 no...

Page 91: ...n system Chain drive Secondary reduction ratio 2 167 Number of drive chain sprocket teeth front rear 18 39 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 857 2nd 2 000 3rd 1 571 4th 1 292 5th 1 115 Chassis Frame type Double cradle Caster angle 25 5 Trail 100 mm Tires Front Type Tubeless tire Size 120 70 ZR17 58W 120 70 ZR17 M C 58W Manufacturer model Dunlop D220F ST M...

Page 92: ...sories Wheels Front Type Cast wheel Size 17 MT 3 50 17 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 50 17 M C MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm Springs shock absorbers Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 13...

Page 93: ...liary light 12 V 4 W 1 Turn signal light 12 V 21 W 4 Meter lighting 12 V 1 7 W 4 Neutral indicator light 12 V 1 7 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 2 Fuses Main fuse 40 A Headlight fuse 15 A Signaling system fuse 15 A Ignition fuse 15 A Turn signal light fuse 15 A E_5ea book Page 4 Tuesday October 2 2001 3 54 PM ...

Page 94: ...IMPERIAL 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 ...

Page 95: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_5ea book Page 1 Tuesday October 2 2001 3 54 PM ...

Page 96: ...E 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 ...

Page 97: ...e frame under the seat See page 3 11 for seat removal and installation procedures 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 E_5ea book Page 2 Tuesday October 2 2001 3 54 PM ...

Page 98: ...el cock 3 10 Fuel consumption tips for reducing 5 4 Fuel gauge 3 3 Fuel tank breather hose 3 10 Fuel tank cap 3 8 Fuses replacing 6 29 H Handlebar switches 3 4 Hazard switch 3 4 Headlight bulb replacing 6 29 Helmet holder 3 12 High beam indicator light 3 2 Horn switch 3 4 I Identification numbers 9 1 Idling speed adjusting 6 13 Ignition circuit cut off system 3 17 Indicator and warning lights 3 2 ...

Page 99: ...e grip and cable checking and lubricating 6 24 Tires 6 14 Tool kit 6 1 Troubleshooting 6 36 Troubleshooting chart 6 37 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 31 Turn signal switch 3 4 V Valve clearance adjusting 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 32 Installing 6 33 Removing 6 32 Wheel rear 6 34 Installing 6 35 Removing 6...

Page 100: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 101: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2001 8 0 3 1 CR E ...

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