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PERIODIC MAINTENANCE AND MINOR REPAIR

6-33

6

EAU03165

Checking and lubricating the
sidestand

The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.

EW000113

WARNING

_

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

_

EAU04282

Lubricating the rear
suspension

The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.

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,
damage and excessive oil leakage.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

Recommended lubricant:

Lithium-soap-based grease

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Summary of Contents for XV1700PC

Page 1: ...5PX 28199 11 LIT 11626 16 36 XV1700PCR XV1700PCRC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

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

Page 4: ...l precautions that must 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...

Page 5: ...MOTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ ...

Page 6: ...CR XV1700PCRC OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition June 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 36 ...

Page 7: ...CRIPTION 2 3 INSTRUMENT 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 ...

Page 8: ......

Page 9: ...SAFETY INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 ...

Page 10: ...EN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who di...

Page 11: ...XCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and bo...

Page 12: ...stem during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modification...

Page 13: ...t fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha ...

Page 14: ...d may limit control ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refuelin...

Page 15: ...e source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline sp...

Page 16: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle ...

Page 17: ...SAFETY INFORMATION 1 1 8 1 California only 2 3 4 5 California only ...

Page 18: ......

Page 19: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 ...

Page 20: ...2 1 2 EAU00026 2 DESCRIPTION Left view 1 Engine oil drain bolt crankcase page 6 11 2 Shift pedal page 3 7 3 Fuel tank cap page 3 9 4 Helmet holder page 3 11 5 Fuses page 6 37 6 Owner s tool kit page 6 2 ...

Page 21: ...ork spring preload adjusting bolt page 3 12 10 Engine oil filter cartridge page 6 11 11 Brake pedal page 3 8 12 Engine oil drain bolt oil tank page 6 10 13 Shock absorber assembly spring preload adjusting nut page 3 13 14 Shock absorber assembly rebound damping force adjusting knob page 3 14 ...

Page 22: ...uments 1 Clutch lever page 3 7 2 Left handlebar switches page 3 6 3 Speedometer page 3 3 4 Tachometer unit page 3 4 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 7 7 Throttle grip page 6 18 8 Brake lever page 3 8 ...

Page 23: ...eedometer 3 3 Tachometer unit 3 4 Handlebar 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 Seat 3 11 Helmet holder 3 11 Adjusting the front fork 3 12 Adjusting the shock absorber assembly 3 13 Sidestand 3 15 Ignition circuit cut off system 3 16 ...

Page 24: ...tart ed The key cannot be removed NOTE _ The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls _ EAU00038 OFF All electrical systems are off The key can be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to th...

Page 25: ...r lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU04878 Fuel level warning light This warning light comes on when the fuel level drops below approximately 0 8 US gal 0 7 Imp gal 3 0 L When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light...

Page 26: ...ing the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the elec trical circuit EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU04031 Speedometer The speedometer shows the riding speed 1 High beam indicator light 2 Right turn signal indicator light 3 Fuel level warning light ...

Page 27: ...el warning light came on a meter lighting control a clock a self diagnosis device NOTE _ Be sure to turn the key to ON before using the SELECT and RESET buttons To switch the odometer the trip meters and the fuel reserve trip meter displays between kilometers and miles press the SELECT button for at least two seconds _ ECA00123 CAUTION _ Do not operate the engine in the ta chometer red zone If ope...

Page 28: ...e after refueling and traveling 3 mi 5 km 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 after five seconds release the SELECT button 4 Push the RESET button to select the desired brightness 5 Push the SELECT button to set the brightness level 6 Turn the key to OFF NOTE _ When adjusting the meter lighting the odometer display will...

Page 29: ... beam and to for the low beam EAU04218 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 the switch returns to the cen ter position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the motor cycle has traveled both about 490 ft 150 m and for approximately 15 sec onds...

Page 30: ...e 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 ignition circuit cut off system See page 3 16 for an explanation of the ignition circuit cut off system EAU00157 Shift ...

Page 31: ... lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Brake pedal ...

Page 32: ...d 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 riding _ EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown ...

Page 33: ...research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol cont...

Page 34: ...the projection on the rear of the seat into the seat holder as shown 2 Push the front of the seat down to lock it in place 3 Remove the key NOTE _ Make sure that the seat is properly se cured before riding _ EAU00263 Helmet holder The helmet holder is located under the seat To secure a helmet to the helmet holder 1 Remove the seat 2 Attach the helmet to the helmet holder and then securely install ...

Page 35: ...000035 WARNING _ 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 turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE ...

Page 36: ...he 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 _ Use the special wrench included in the owner s tool kit to make the ad justment 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 short...

Page 37: ...orce adjusting mecha nism may not exactly match the above specifications due to small differences 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 modify the specifications as nec essary _ Spring preload Minimum soft Distance A 2...

Page 38: ...idestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorcycle 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 _ EW000044 WARNING _ The motorcycle must not be...

Page 39: ...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 pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 WARNING _ If a m...

Page 40: ...the sidestand up 7 Keep the 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 defe...

Page 41: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 ...

Page 42: ...ssary add recommended oil to specified level Check vehicle for oil leakage 6 9 6 10 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 24 6 26 6 28 Rear brake Check operation If soft or spongy ...

Page 43: ...k tire condition and tread depth Check air pressure Correct if necessary 6 19 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 32 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 33 Chassis fasteners Mak...

Page 44: ......

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Shifting 5 3 Engine break in 5 5 Parking 5 5 ...

Page 46: ...ting in a possible loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU04440 Starting and warming up a cold engine In order for the ignition circuit cut ...

Page 47: ...eutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 3 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt 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 _ ECA00055 C...

Page 48: ...on 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 _ EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release t...

Page 49: ...tch lever in and use the brakes to stop the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU02974 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below CF 04E Acceleration shift point mi h km h Deceleration shift point mi h ...

Page 50: ...ged operation above 3 500 r min ECA00026 CAUTION _ After 600 mi 1 000 km of operation the engine oil and transfer case oil must be changed and the oil filter cartridge replaced _ 1 000 mi 1 600 km and beyond The vehicle can now be operated nor mally EC000053 CAUTION _ Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediat...

Page 51: ...on 6 25 Adjusting the rear brake light switch 6 25 Checking the front and rear brake pads 6 26 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Drive belt slack 6 29 Checking and lubricating the cables 6 31 Checking and lubricating the throttle grip and cable 6 31 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and clutch levers 6 32 Che...

Page 52: ...e EW000060 WARNING _ If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you _ EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO V...

Page 53: ...rformance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE _ If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and...

Page 54: ... clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hose for cracks or damage Replace if necessary 5 Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary 6 Electronic fuel injection C...

Page 55: ...essary 4 Front brake Check operation and fluid leakage See NOTE page 6 6 Correct if necessary Replace brake fluid 5 Rear brake Check operation and fluid leakage See NOTE page 6 6 Correct if necessary Replace brake fluid 6 Clutch Check operation and free play Correct if necessary 7 Transfer case oil Check vehicle for leakage Replace every 16 000 mi 25 000 km or 24 months SAE 80 API GL 4 hypoid gear...

Page 56: ... Lithium soap based grease all purpose grease 14 Sidestand switch Check and clean or replace if necessary 15 Front fork Check operation and for leakage 16 Steering bearings Check bearing assembly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap based grease all purpose grease Repack 17 Wheel bearings Check bearings for smooth rotation 18 Rear suspen sion link piv...

Page 57: ...inders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 19 Drive belt Check belt tension Adjust if necessary Every 2 500 mi 4 000 km No ITEM ROUTINE T...

Page 58: ...mally and all spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color 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 pl...

Page 59: ...ned to the speci fied torque as soon as possible _ EAU00499 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this motorcycle make sure to check the following Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure that the canister breather is not block...

Page 60: ...arm it up until the engine oil has reached a nor mal temperature of 140 F 60 C let it continue to idle for ten sec onds and then turn the engine off NOTE _ To achieve the proper engine oil tem perature for an accurate oil level read ing the engine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature _ 4 Wait a few minutes until the oil...

Page 61: ...is se curely 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 seat See page 3 11 for seat removal and installation procedures 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 ...

Page 62: ...rom the crankcase 7 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 8 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 _ 1 Engine oil drain bolt crankcase 1 Oil filter cartridge 2 Oil filter wrench 1 O ring ...

Page 63: ...emical additives Do not use oils with a diesel speci fication of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 14 Install the engine oil filler cap 15 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately t...

Page 64: ... which is locat ed in the air filter case the other is lo cated in the silencer case The air filter elements should be re placed at the intervals specified in the periodic maintenance and lubrication 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 seat See page 3 11 for s...

Page 65: ...e nuts c Disconnect fuel hose B from the joint as shown ECA00121 CAUTION _ Place a towel or cloth under the fuel hose joints when discon necting hoses A and B to pre vent fuel from spilling onto the vehicle Make sure that no foreign mate rial enters the fuel hose joints when the hoses are disconnect ed _ 1 Fuel hose A 1 Nut 2 1 Fuel hose B ...

Page 66: ...e the hoses as shown and then remove the fuel tank by pull ing it upward 4 Remove the air filter case bolts 5 Loosen the air filter joint clamp screw and then pull off the air filter case 1 Hose 2 1 Air filter case 2 Bolt 2 1 Air filter joint clamp screw ...

Page 67: ... should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 9 Remove the clamp from the check hose and then remove the plug to drain any accumulated water 10 Install the plug and the clamp 11 Install the air filter case cover by installing the screws 12 Install the air filter case by pushing it onto the air filter joint ...

Page 68: ...ut have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched _ b Install the nuts c Connect fuel hose A 15 Install the air induction system cover by installing the bolts 16 Install the seat Silencer case air filter element To replace the air filter element 1 Remove the fuel tank See steps 1 3 under Air filter case...

Page 69: ...filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 5 Install the silencer air filter case cover by installing the screws 6 Install the fuel tank See step 14 under Air filter case element EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 0 16 0 24 in 4 6 mm at the throttle grip Periodically check the throttle cabl...

Page 70: ...ecked and if necessary 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 22E CE 16E Tire air pressu...

Page 71: ...d the maxi mum load of the motorcycle Opera tion of an overloaded motorcycle could cause tire damage an acci dent or even injury _ Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replace...

Page 72: ...ways 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 valve core 3 Tire air valve cap with seal FRONT Manufacturer Size Model Bridgestone 120 70 ZR18 59W BT020F G 120 70 ZR18 M C 59W Dunlop 120 70 ZR18 59W D220F ST G ...

Page 73: ...ys adjust the tire air pres sure according to the operating conditions _ EAU03773 Cast wheels To maximize 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 be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smal...

Page 74: ...ha approved accessories or replacement 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 _ EAU00694 Adjusting the clutch lever free play The clutch lever free play should mea s...

Page 75: ...ically check the brake lever free play and if necessary adjust it as fol lows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut EW000099 WARNING _ After adjusting the brake lever free play check the free play and make sure that th...

Page 76: ...otorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident _ EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting...

Page 77: ... groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04434 Rear brake pads 1 Remove brake caliper bolt A loos en brake caliper bolt B and then tilt the...

Page 78: ...plenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty brake fluid otherwise the rubber seals m...

Page 79: ...al for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake...

Page 80: ...ck hole are 0 2 in 5 mm apart _ 3 Note the position of the drive belt with a force of 10 lbf 4 5 kgf 45 N 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 measure ment noted in step 3 5 If the drive belt slack is incorrect adjust it as follo...

Page 81: ...of the swingarm make sure that both belt pullers are in the same posi tion for proper wheel alignment _ ECA00025 CAUTION _ Improper drive belt slack will over load the engine Keep the drive belt slack within the specified range _ 4 Tighten the locknuts the axle nut and the brake caliper bracket bolt to the specified torques 1 Brake caliper bracket bolt 1 Locknut 2 2 Drive belt slack adjusting bolt...

Page 82: ...vement Replace damaged ca bles as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03370 Checking and lubricating the brake and shift pedals The oper...

Page 83: ...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 all purpose grease ...

Page 84: ...ng points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart 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 ther...

Page 85: ...ler check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be 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 dang...

Page 86: ... 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 tities of...

Page 87: ...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 charge a s...

Page 88: ...rn off the electrical circuit in question 3 Remove the blown fuse and then install a new fuse of the specified amperage 1 Battery band 2 Battery cover 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Electronic fuel injection fuse 5 Odometer and clock fuse backup fuse 6 Auto decompression fuse 7 Spare fuse 3 8 ECU fuse 1 Main fuse 2 Spare main fuse Specified fuses Main fuse 30 A Headligh...

Page 89: ...evice operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 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 the screws 2 Disconnect the headl...

Page 90: ...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 91: ... 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 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 the screws EC000108 CAUTION _ Do not overtighten the screws oth erwise the lens may break _ 1 Screw 2 1 Turn ...

Page 92: ... 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 ECA00107 CAUTION _ Do not overtighten the nuts other wise the lens may break _ 1 Nut 2 2 Washer 2 3 Rubber damper 2 4 Licence plate light unit 1 Nu...

Page 93: ... wheel off the ground by using 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 EAU01008 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 ...

Page 94: ...no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Batt...

Page 95: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 ...

Page 96: ...ps 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 especially on spoked wheels If such products are used on hard to remo...

Page 97: ... washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt ...

Page 98: ...r waxes many of which contain abrasives that may mar the paint or protective finish 7 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before operati...

Page 99: ...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 spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head ...

Page 100: ... the wheels a little every 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 30 F 0 C or more than 90 F 30 C For more informa ...

Page 101: ...SPECIFICATIONS 8 Specifications 8 1 ...

Page 102: ... 113 mm Compression ratio 8 36 1 Starting system Electric starter Lubrication system Dry sump Engine oil Type YAMALUBE 4 20W 40 or SAE 20W 40 Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 3 9 US qt 3 3 lmp qt 3 7 L With oil filter cartridge replacement 4 3 US qt 3 6 lmp qt 4 1 L Total amount dry engine 5 3 US qt 4 4 lmp qt 5 ...

Page 103: ...GK DPR7EA 9 or DENSO X22EPR U9 Gap 0 03 0 04 in 0 8 0 9 mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 532 Secondary reduction system Belt drive Secondary reduction ratio 2 393 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 375 2nd 1 579 3rd 1 160 4th 0 935 5th 0 800 Chassis Frame type Double cradle Caster an...

Page 104: ...Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 18 MT 3 50 18 M C MT 3 50 Rear Type Cast wheel Size 17 MT 6 00 17 M C MT 6 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring Shock absorber Front Coil spring oil...

Page 105: ...light 12 V 23 8 W 2 Rear turn signal light 12 V 23 W 2 Meter lighting LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED 2 Fuel level warning light LED Engine trouble warning light LED Fuses Main fuse 30 A Ignition fuse 10 A Signaling system fuse 10 A Headlight fuse 15 A Electronic fuel injection fuse 15 A ECU fuse 10 A Auto decompression fuse 15 A Odomet...

Page 106: ......

Page 107: ...ation number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 ...

Page 108: ... LABEL INFORMATION CA 01E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE _ The vehicle identification num...

Page 109: ...l label is affixed to the 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 ...

Page 110: ...aints it may open an investigation 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 NH...

Page 111: ...ted into any new ve 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 modif...

Page 112: ...rranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 ...

Page 113: ... 6 9 28 000 mi 43 000 km or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 114: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ...

Page 115: ...CONSUMER INFORMATION 9 8 9 ...

Page 116: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S ...

Page 117: ...CONSUMER INFORMATION 9 10 9 ...

Page 118: ...t fork checking 6 33 Fuel 3 9 Fuel level warning light 3 2 Fuel tank cap 3 9 Fuses replacing 6 37 H Handlebar switches 3 6 Headlight bulb replacing 6 38 Helmet holder 3 11 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 License plate light bulb repl...

Page 119: ... Throttle cable free play adjusting 6 18 Throttle grip and cable checking and lubricating 6 31 Tires 6 19 Tool kit 6 2 Transfer case oil 6 13 Troubleshooting 6 42 Troubleshooting chart 6 43 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 40 Turn signal switch 3 6 V Valve clearance adjusting 6 19 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Whee...

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Page 122: ...PRINTED IN JAPAN 2002 07 0 5 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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