Yamaha YZF Owner'S Manual Download Page 59

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-7

EAU01065

Removing and installing
cowlings

The cowlings shown above need to be
removed to perform some of the main-
tenance jobs described in this chapter.

Refer to this section each time a cowl-
ing needs to be removed and installed.

EAU04277

Cowlings A and C

To remove one of the cowlings

1. Remove the bolts.

1. Cowling A
2. Cowling B

1. Cowling C
2. Cowling D

1. Bolt (

3 on each side)

U5AH16.book Page 7 Wednesday, May 8, 2002 9:16 AM

Summary of Contents for YZF

Page 1: ...5AH 28199 16 LIT 11626 16 10 YZF600RR YZF600RRC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the 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 motorcycle To maintain these h...

Page 4: ...t 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: ...PT 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 U5AH16 book Page 2 Wednesday May 8 2002 9 16 AM ...

Page 6: ...UAL 2002 by Yamaha Motor Corporation U S A 1st edition March 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 10 U5AH16 book Page 3 Wednesday May 8 2002 9 16 AM ...

Page 7: ...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 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 8: ...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 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 9: ...ANICAL 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 did not see the motorcycle ...

Page 10: ...ornering 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 both feet on the operator ...

Page 11: ...ration 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 Modifications may also make your mot...

Page 12: ... These items in cluding such items 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 accessor...

Page 13: ...ity 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 refueling b Take care not to spi...

Page 14: ...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 carburetor or 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 spills on your skin...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5AH16 book Page 7 Wednesday May 8 2002 9 16 AM ...

Page 16: ...Y INFORMATION 1 1 8 1 2 3 4 5 6 7 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 2835Y 00 U5AH16 book Page 8 Wednesday May 8 2002 9 16 AM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 18: ...d adjusting ring page 3 14 4 Shock absorber assembly rebound damping force adjusting knob page 3 14 5 Shock absorber assembly compression damping force adjusting screw page 3 15 6 Storage compartment page 3 11 7 Helmet holder page 3 10 8 Grab bar 9 Shift pedal page 3 6 10 Radiator U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 19: ...nt fork spring preload adjusting bolt page 3 12 15 Front fork rebound damping force adjusting screw page 3 12 16 Radiator cap page 6 18 17 Front fork compression damping force adjusting screw page 3 13 18 Engine oil level check window page 6 13 19 Brake pedal page 3 7 20 Engine oil filler cap page 6 13 U5AH16 book Page 2 Wednesday May 8 2002 9 16 AM ...

Page 20: ...age 3 5 3 Starter choke lever page 3 9 4 Speedometer unit page 3 3 5 Tachometer page 3 3 6 Coolant temperature gauge page 3 4 7 Right handlebar switches page 3 5 8 Brake lever page 3 6 9 Throttle grip page 6 22 10 Main switch steering lock page 3 1 U5AH16 book Page 3 Wednesday May 8 2002 9 16 AM ...

Page 21: ...tch lever 3 6 Shift pedal 3 6 Brake lever 3 6 Brake pedal 3 7 Fuel tank cap 3 7 Fuel 3 8 Starter choke lever 3 9 Seat 3 9 Helmet holder 3 10 Storage compartment 3 11 Adjusting the front fork 3 11 Adjusting the shock absorber assembly 3 13 Matching the front and rear suspension settings 3 16 Luggage strap holders 3 17 Sidestand 3 17 Ignition circuit cut off system 3 18 U5AH16 book Page 1 Wednesday ...

Page 22: ...ed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be removed 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 ...

Page 23: ...arning light comes on when the fuel level drops below approximately 3 1 L 0 7 Imp gal 0 8 US gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push the start switch If the...

Page 24: ... CAUTION Do not operate the engine in the ta chometer red zone Red zone 13 200 r min and above EAU00105 Self diagnosis device This model is equipped with a self di agnosis device for the following electri cal circuits throttle position sensor fuel level warning light If any of those circuits are defective the tachometer will repeatedly display the following error code CB 11E Use the table below to...

Page 25: ...mage EAU01652 Coolant temperature gauge With the key in the ON position the coolant temperature gauge indicates the temperature of the coolant The coolant temperature varies with chang es in the weather and engine load If the needle reaches or enters the red zone stop the motorcycle and let the engine cool See page 6 47 for further instructions EC000002 CAUTION Do not operate the engine if it is o...

Page 26: ...re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See p...

Page 27: ...ation with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handlebar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn...

Page 28: ...l tank cap can be opened To close the fuel tank cap 1 Push the 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 s...

Page 29: ...aha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a 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 tha...

Page 30: ... off the starter choke ECA00038 CAUTION Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke EAU04158 Seat To remove the seat 1 Insert the key into the helmet hold er lock and then turn it as shown 2 Pull the seat off 1 Starter choke ...

Page 31: ...efore riding _ EAU00261 Helmet holder To open the helmet holder insert the key into the 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 Seat holder 2 Projection 2 1 Helmet ...

Page 32: ...er 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 EAU01862 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting scre...

Page 33: ...ease the rebound damping force and thereby harden the rebound damping turn the adjusting screw on each fork leg in direction a To de crease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in direction b CI 02E 1 Spring preload adjusting bolt 1 Current setting 2 Front fork cap bolt Setting Minimum soft 8 Standard 5 Maximum hard 1 1 Rebound ...

Page 34: ...er of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary EAU03643 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping force ad justing knob and...

Page 35: ... number of clicks of the rebound damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual num ber of clicks always represents the entire adjusting range To obtain a pre cise adjustment it would be advisable to check the number of clicks of the re bound damping force adjusting mecha nism and to modify the specifications as n...

Page 36: ...on be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber 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 w...

Page 37: ...conditions CI 05E EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload Compression damping force Rebound damping force Spring preload Compression damping force Rebound damping force Rider only 1 8 1 10 1 10 1 5 1 6 3 25 With passenger 1 8 1 10 1 10 3 7 1 4 3 10 U5A...

Page 38: ...ation of the ignition circuit cut off system EW000044 WARNING The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling...

Page 39: ...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 malfunction is noted have ...

Page 40: ...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 defective The motorcycle sho...

Page 41: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 42: ...engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 13 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 16 6 17 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 spe...

Page 43: ...Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 33 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 34 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 34 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signa...

Page 44: ...pection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 WARNING If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle U5AH16 book Page 3 Wednesday May 8 2002 9 16 AM ...

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 46: ... 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 _ EAU01164 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable star...

Page 47: ... they should go off when the start switch is released If the oil level warning light flick ers or remains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If the warning light does not come on when push ing the start switch or if it does not go off after starting wit...

Page 48: ...5 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerati...

Page 49: ...lutch lever slowly 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral position 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear N...

Page 50: ...ts in the engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided EAU03749 0 1 000 km 0 600 mi Avoid prolonged operation above 6 500 r min 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 8 000 r min EC000052 CAUTION _ After 1 000 km 600 mi of ope...

Page 51: ...ne break in period immediately have a Yamaha dealer check the vehi cle _ EAU00460 Parking When parking stop the engine and then remove the 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 U5AH16 b...

Page 52: ...usting the rear brake light switch 6 28 Checking the front and rear brake pads 6 29 Checking the brake fluid level 6 29 Changing the brake fluid 6 30 Drive chain slack 6 31 Lubricating the drive chain 6 32 Checking and lubricating the cables 6 33 Checking and lubricating the throttle grip and cable 6 33 Checking and lubricating the brake and shift pedals 6 33 Checking and lubricating the brake and...

Page 53: ...RTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND E...

Page 54: ... 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 render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ U5AH16 book Page 2 Wednesday May 8 2002 9 16 AM ...

Page 55: ... 30 000 mi 42 000 km or 42 months 2 Spark plugs Check condition Adjust gap and clean 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 Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for leakage Tighten if necessary Replace ...

Page 56: ...se for cracks or damage Replace if necessary Replace coolant every 24 months Ethylene glycol anti freeze coolant Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 6 Replace pads if necessary 6 Clutch Check operation Correct if necessary 7 Control and meter cables Apply chain lube thoroughly Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE 8 Swingarm pi...

Page 57: ...y chain lube lightly Lithium soap based grease all purpose grease 15 Drive chain Check chain slack alignment condition Adjust and lubricate chain thoroughly Special O ring chain lubricant Every 600 mi 1 000 km and after washing the motorcycle or riding in the rain 16 Wheel bearings Check bearing for smooth rotation 17 Sidestand pivot Check operation and lubricate Apply chain lube lightly Lithium s...

Page 58: ...d level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Engine oil type Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above Yamalube 4 10W 30 or engine oil SAE 10W 30 API SE for temperatures of 15 C 60 F or below _ U5AH16 book Pa...

Page 59: ... perform some of the main tenance jobs described in this chapter Refer to this section each time a cowl ing needs to be removed and installed EAU04277 Cowlings A and C To remove one of the cowlings 1 Remove the bolts 1 Cowling A 2 Cowling B 1 Cowling C 2 Cowling D 1 Bolt 3 on each side U5AH16 book Page 7 Wednesday May 8 2002 9 16 AM ...

Page 60: ...g off To install the cowling 1 Connect the turn signal connec tors and for the left side cowling also the auxiliary light coupler 2 Place the cowling in the original position and then install the bolts Bolt 13 Left side Right side 1 Bolt 5 on each side 1 Auxiliary light coupler 2 Turn signal connector 2 Left side Right side U5AH16 book Page 8 Wednesday May 8 2002 9 16 AM ...

Page 61: ...ition and then install the screws 2 Install the seat EAU04278 Cowling D To remove the cowling 1 Remove the seat and cowling B See page 3 9 for seat removal and installation procedures 2 Remove the grab bar by removing the bolts 3 Remove the screw and then pull the cowling off as shown To install the cowling 1 Place the cowling in the original position and then install the screw 2 Install the grab ...

Page 62: ...k plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed 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 medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a di...

Page 63: ...m the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap Specified spark plu...

Page 64: ...ster to prevent the discharging of fuel vapor into the atmosphere Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure the vent hose is not blocked Clean it if necessary 1 Fuel tank 2 Canister 3 Vent hose 4 Carburetor U5AH16 book Page 12 Wednesday May 8 2002 9 16 AM ...

Page 65: ...nd then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil ...

Page 66: ...ter wrench is available at a Yamaha dealer _ 6 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 _ 7 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt Left side 1 Oil filter cartridge 2 Oil filter wrench 1 O ring Tightening torque Oil filter c...

Page 67: ...ral minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ EC000067 CAUTION _ If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle _ 11 Turn the ...

Page 68: ...mark remove the seat See page 3 9 for seat re moval and installation proce dures and then open the coolant reservoir cap 4 Add coolant or distilled water to raise the coolant to the specified level close the coolant reservoir cap and then install the seat EC000080 CAUTION _ If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is har...

Page 69: ...val and installation procedures 3 Remove cowling D See page 6 9 for cowling removal and installa tion procedures 4 Remove the coolant reservoir by removing the bolts 5 Drain the coolant from the coolant reservoir 6 Remove cowlings A and C See page 6 7 for cowling removal and installation procedures 7 Remove the fuel tank bolts and then lift the fuel tank Do not re move the fuel hoses EW000071 WARN...

Page 70: ... drain bolts to drain the cooling system 13 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 14 Install the water pump drain bolt and cylinder drain bolts and then tighten them to the specified torques 15 Install the coolant reservoir by in stalling the bolts 1 Clamp screw 2 2 Right air intake duct 1 Radiator cap 1 Water pump drain bolt 2 Cylinder d...

Page 71: ... Yamaha dealer check the cooling system 21 Install the right air intake duct and then tighten the clamp screws 22 Place the fuel tank in the original position and then install the bolts 23 Install the cowlings 24 Install the seat EAU04281 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 a...

Page 72: ...filter element out 6 Clean the air filter element with solvent and then squeeze the re maining solvent out 7 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out NOTE _ The air filter element should be wet but not dripping _ 8 Insert the air filter element into the air filter case 1 Air filter case cover 2 Screw 8 1 Air filter element ...

Page 73: ...e not damaged If any fuel hose is damaged do not start the engine but 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 _ 11 Install the seat EAU00626 Checking the air vent hose Periodically check the air vent hose for dust or water that may be deposited in the hose If dust or water is found re move the ho...

Page 74: ...able free play The throttle cable free play should measure 3 7 mm 0 12 0 28 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted ...

Page 75: ...oosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if approve...

Page 76: ...en a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Tire sidewall 2 Tire wear indicator a T...

Page 77: ...gh speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions FRONT Manufac...

Page 78: ...to develop its optimal characteris tics EAU00691 Accessories and replacement parts EW000098 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine ...

Page 79: ...lt in direction b 3 Tighten the locknut NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 42 mm 1 65 in below the top of the footrest as shown Periodically check the brake ...

Page 80: ...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 nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in directio...

Page 81: ...oint that the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU03294 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective 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 wo...

Page 82: ... Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to 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 af...

Page 83: ... motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU03752 To adjust the drive chain slack 1 Loosen the axle nut then loosen the locknut at each end of the swingarm 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the dri...

Page 84: ...ied in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 CAUTION The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION To prevent damaging the O rings do not clean the...

Page 85: ... 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 operation of the brake and shif...

Page 86: ...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 Recommended lubricant Lithium soap based gre...

Page 87: ...ion 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be c...

Page 88: ...maha 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 If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5AH16 book Page 36 Wednesday May 8 2002 9 16 AM ...

Page 89: ...pt 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 enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the bat...

Page 90: ...ir cuits are located under the seat See page 3 9 for seat removal and installa tion procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage...

Page 91: ...lectrical system EAU04160 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder U5AH16 book Page 39 Wednesday M...

Page 92: ...ht bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage higher than speci fied _ 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU01623 Replacing the tail brake light bulb 1 Remove the tail b...

Page 93: ...r mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the f...

Page 94: ...f the ground according to the procedure on page 6 41 5 Remove the brake hose holders on each side by removing the bolts 6 Remove the brake calipers on each side by removing the bolts 7 Pull the wheel axle out remove the speedometer gear unit and then remove the wheel ECA00046 CAUTION Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut 1 Sp...

Page 95: ...lt and the brake caliper bolts to the specified torques 7 Install the brake hose holders by installing the bolts 8 Connect the speedometer cable 9 Install the front fender by installing the bolts 10 Push down hard on the handlebar several times to check for proper fork operation EAU04197 Rear wheel To remove the rear wheel EW000122 WARNING _ It is advisable to have a Yamaha dealer service the whee...

Page 96: ...t and the drive chain slack adjusting nut on both sides of the swingarm 6 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE _ The drive chain does not need to be disassembled in order to remove and install the wheel _ 7 Pull the wheel axle out along with the right wheel axle guide remove the brake caliper bracket and then remove the wheel ECA00048 CAUTION _ Do not ...

Page 97: ... into the brake torque rod bolt EWA00051 WARNING _ Always use a new cotter pin for the brake torque rod bolt _ EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooti...

Page 98: ...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 Operate the electric starter 4 Battery The engine turns over quickly The engine tu...

Page 99: ...e hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check...

Page 100: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 101: ...ectrical 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 102: ...marks If the wind shield 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 clea...

Page 103: ... paint 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 ...

Page 104: ...vent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bor...

Page 105: ...ery month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 30 F or more than 30 C 90 F For more informa tion on storing the bat...

Page 106: ...SPECIFICATIONS 8 Specifications 8 1 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 107: ...ting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 6 L 2 3 Imp qt 2 8 US qt With oil filter cartridge replacement 2 9 L 2 6 Imp qt 3 1 US qt Total amount dry engine 3 5 L 3 1 Imp qt 3 7 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 ...

Page 108: ...isc Transmission Primary reduction system Spur gear Primary reduction ratio 1 708 Secondary reduction system Chain drive Secondary reduction ratio 3 133 Number of drive chain sprocket teeth front rear 15 47 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 846 2nd 1 947 3rd 1 545 4th 1 333 5th 1 190 6th 1 074 Chassis Frame type Diamond Caster angle 25 Trail 97 mm 3 82 in...

Page 109: ...psi Rear 290 kPa 2 90 kgf cm2 42 psi High speed riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 50 17 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 00 17 M C MT 5 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right f...

Page 110: ...dlight 12 V 60 55 W 1 Tail brake light 12 V 8 27 W 1 Front turn signal position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 W 2 Meter lighting 12 V 1 7 W 4 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 1 Fuel level warning light 12 V 3 4 W 1 Fuses Main fuse 30 A Headlight fuse 20 A Sign...

Page 111: ... 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 U5AH16 book Page 1 Wednesday May 8 2002 9 16 AM ...

Page 112: ... 01E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify ...

Page 113: ...he frame under the seat See page 3 9 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 U5AH16 book Page 2 Wednesday May 8 2002 9 16 AM ...

Page 114: ...estigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tr...

Page 115: ...e for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 0...

Page 116: ...s 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 km or 30 months 24 000 m...

Page 117: ... 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 U5AH16 book Page 6 Wednesday May 8 2002 9 16 AM ...

Page 118: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5AH16 book Page 7 Wednesday May 8 2002 9 16 AM ...

Page 119: ...CONSUMER INFORMATION 9 8 9 U5AH16 book Page 8 Wednesday May 8 2002 9 16 AM ...

Page 120: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S U5AH16 book Page 9 Wednesday May 8 2002 9 16 AM ...

Page 121: ...CONSUMER INFORMATION 9 10 9 U5AH16 book Page 10 Wednesday May 8 2002 9 16 AM ...

Page 122: ...ge 6 13 Engine stop switch 3 5 F Front and rear suspension settings 3 16 Front fork adjusting 3 11 Front fork checking 6 35 Fuel 3 8 Fuel level warning light 3 2 Fuel tank cap 3 7 Fuses replacing 6 38 H Handlebar switches 3 5 Headlight bulb replacing 6 39 Helmet holder 3 10 High beam indicator light 3 2 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 18 Indicator and...

Page 123: ...r 3 3 Tail brake light bulb replacing 6 40 Throttle cable free play adjusting 6 22 Throttle grip and cable checking and lubricating 6 33 Tires 6 23 Tool kit 6 1 Troubleshooting 6 45 Troubleshooting charts 6 46 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 41 Turn signal switch 3 5 V Valve clearance adjusting 6 22 Vehicle identification number 9 1 W Warranty extended 9 9 Warran...

Page 124: ...PRINTED IN JAPAN 2002 04 1 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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