Yamaha YZF600RC Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

6

EAU22020

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the clutch le-

ver.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt 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.

EAU22270

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 direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).

1. Locknut

2. Clutch lever free play adjusting bolt
3. Clutch lever free play

1. Rear brake light switch

2. Rear brake light switch adjusting nut

U5AH1BE0.book Page 25 Thursday, May 18, 2006 3:45 PM

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Summary of Contents for YZF600RC

Page 1: ...5AH 28199 1B YZF600RW C OWNER S MANUAL LIT 11626 20 25 ...

Page 2: ...EAU10041 U5AH1BE0 book Page 1 Thursday May 18 2006 3 45 PM ...

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

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

Page 5: ...TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without notice U5AH1BE0 book Page 2 Thursday May 18 2006 3 45 PM ...

Page 6: ...poration U S A 1st edition May 2006 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 20 25 AFFIX DEALER LABEL HERE U5AH1BE0 book Page 3 Thursday May 18 2006 3 45 PM ...

Page 7: ...AINTENANCE 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings 6 8 Checking the spark plugs 6 10 Canister for California only 6 11 Engine oil and oil filter cartridge 6 12 Coolant 6 15 Cleaning the air filter element 6 18 Checking the air vent hose 6 20 Air intake duct 6 20 Carburetor...

Page 8: ...b 6 37 Supporting the motorcycle 6 38 Front wheel 6 38 Rear wheel 6 40 Troubleshooting 6 42 Troubleshooting charts 6 43 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARR...

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

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

Page 11: ... Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clear...

Page 12: ... ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall ov...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5AH1BE0 book Page 5 Thursday May 18 2006 3 45 PM ...

Page 14: ...lkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 1 2 3 California only 4 5 6 7 3 kg 7 lbs Cold tire normal pressure should be set as follows 3XW 21668 A1 U5AH1BE0 book Page 6 Thursday May 18 2006 3 45 PM ...

Page 15: ...ting ring page 3 12 4 Shock absorber assembly rebound damping force adjusting knob page 3 12 5 Shock absorber assembly compression damping force adjusting screw page 3 12 6 Storage compartment page 3 10 7 Helmet holder page 3 9 8 Grab bar 9 Shift pedal page 3 6 10 Radiator page 6 15 U5AH1BE0 book Page 1 Thursday May 18 2006 3 45 PM ...

Page 16: ...t fork spring preload adjusting bolt page 3 10 5 Front fork rebound damping force adjusting screw page 3 10 6 Radiator cap page 6 15 7 Front fork compression damping force adjusting screw page 3 10 8 Engine oil level check window page 6 12 9 Brake pedal page 3 6 10 Engine oil filler cap page 6 12 U5AH1BE0 book Page 2 Thursday May 18 2006 3 45 PM ...

Page 17: ...s page 3 4 3 Starter choke lever page 3 8 4 Speedometer unit page 3 3 5 Tachometer page 3 3 6 Coolant temperature gauge page 3 4 7 Right handlebar switches page 3 4 8 Brake lever page 3 6 9 Throttle grip page 6 21 10 Main switch steering lock page 3 1 U5AH1BE0 book Page 3 Thursday May 18 2006 3 45 PM ...

Page 18: ... LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK wh...

Page 19: ... have a Yamaha dealer check the electri cal circuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU11320 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 1 L 0 82 US gal 0 68 Imp gal When this occurs refuel as soon as pos...

Page 20: ...one Red zone 13200 r min and above EAU11981 Self diagnosis device This model is equipped with a self diag nosis device for the following electrical circuits throttle position sensor fuel level warning light If any of those circuits are defective the tachometer will repeatedly display the following error code Use the table below to identify the faulty electrical circuit If the tachometer displays s...

Page 21: ...ature 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 vehicle and let the en gine cool See page 6 43 CAUTION ECA10020 Do not operate the engine if it is overheated EAU12346 Handlebar switches Left Right 1 Coolant temperature gauge 2 Coolant temperature gauge red zone 1 Dimmer switch 2 Turn signal switc...

Page 22: ...ns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU42090 The oil level warning light and fuel level warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lev...

Page 23: ...quipped with a po sition adjusting dial To adjust the dis tance between the brake 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 EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear ...

Page 24: ...k 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 WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13211 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not over...

Page 25: ...containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13610 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move ...

Page 26: ...he key NOTE Make sure that the seat is properly se cured before riding EAU14290 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 WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and po...

Page 27: ...ng the vehicle be careful not to let any water enter the storage compartment EAU14741 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 screws WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload To increas...

Page 28: ...ion damping turn the adjusting screw on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b 1 Current setting 2 Front fork cap bolt Spring preload setting Minimum soft 8 Standard 5 Maximum hard 1 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 10 clic...

Page 29: ...h a spring preload adjust ing ring a rebound damping force ad justing knob and a compression damping force adjusting screw CAUTION ECA11220 Never attempt to turn the spring pre load and rebound damping force ad justing mechanisms beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease...

Page 30: ...decrease the setting by turning the ad justing screw To soften the compres sion damping increase the setting by turning the adjusting screw Make sure that the position indicator is aligned with the appropriate setting WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber Th...

Page 31: ...e vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact ...

Page 32: ... in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EW...

Page 33: ...er the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle s...

Page 34: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 35: ...oft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 26 6 26 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reserv...

Page 36: ...s Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights sig...

Page 37: ...pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 15 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA10220 If the fuel level warning light comes on check the fuel level and if nec essary refuel as so...

Page 38: ...shing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5 After starting the engine move the starter choke back halfway CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 6 When the engine is warm turn the starter choke off NOTE The engine...

Page 39: ...ven with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not de...

Page 40: ...EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for...

Page 41: ...meter red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17200 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope ...

Page 42: ...SIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES EAU17...

Page 43: ...ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U5AH1BE0 book Page 2 Thursday May 18 2006 3 45 PM ...

Page 44: ...necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synchro nization Adjust synchronization of carbu re...

Page 45: ...ch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam age Rep...

Page 46: ...onths Repack 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand ...

Page 47: ...ace 22 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 Front and rear brake switches Check operation 24 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 1300...

Page 48: ...ls 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 25 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 26 Lights signa...

Page 49: ...bed in this chapter Refer to this section each time a cowl ing needs to be removed and installed EAU42330 Cowlings A and C To remove one of the cowlings 1 Remove the screws 2 Disconnect the turn signal light lead connectors and then take the cowling off 1 Cowling A 2 Cowling B 1 Cowling C 2 Cowling D 1 Screw 1 Screw 1 Screw U5AH1BE0 book Page 8 Thursday May 18 2006 3 45 PM ...

Page 50: ...he cowling 1 Place the cowling in the original position and then install the screws 2 Install the seat EAU19021 Cowling D To remove the cowling 1 Remove the seat and cowling B See pages 3 9 and 6 8 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 cowling D in the original po sition and then install the screw 2 Inst...

Page 51: ...the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 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 oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha deale...

Page 52: ...rn 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 EAU19672 Canister for California only This model is equipped with a canister 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 dam aged 1 Spark plug gap Spark plug...

Page 53: ...cking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and 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 at or be...

Page 54: ...d 5 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter 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 with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil filler...

Page 55: ...n let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicl...

Page 56: ...or below the minimum level mark open the coolant reservoir cap 5 Add coolant or distilled water to raise the coolant to the specified level close the coolant reservoir cap and then install the seat CAUTION ECA10471 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant...

Page 57: ...the fuel hoses WARNING EWA10410 Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 5 Remove the right air intake duct by loosening the clamp screws 6 Remove the radiator cap WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 7 Place a container under the engin...

Page 58: ...Hard water or salt water is harmful to the engine You may use soft water if you can t get distilled water 17 Start the engine let it idle for sev eral minutes and then turn it off 18 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 1 Water pump drain bolt 2 Cylinder dra...

Page 59: ...ent The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the seat See page 3 9 2 Remove the fuel tank bolts 3 Lift the fuel tank to position it away from the air filter case Do not dis connect the fuel hoses WARNING EWA10410 Make ...

Page 60: ...e air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by in stalling the screws and bolt 10 Place the fuel tank in the original position and then install the bolts WARNING EWA10420 Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but ha...

Page 61: ...cle with the air vent hose removed EAU21210 Air intake duct Check that the screen of the intake duct is not blocked Clean the screen if nec essary EAU21271 Carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional kn...

Page 62: ...pecified in the periodic maintenance and lubrication chart EAU21750 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when...

Page 63: ...hows 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 replaced WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts inc...

Page 64: ... following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high 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 m...

Page 65: ...it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamah...

Page 66: ...lutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU22270 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 ...

Page 67: ...ble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indi cator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22580 Checking the brake fluid level Front brake Rear brake Insufficient brake fluid may allow air to enter the brake system possibly caus ing i...

Page 68: ... water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly h...

Page 69: ...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 drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both adjusting nuts are in the same po sition f...

Page 70: ... chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION EC...

Page 71: ...maged ca bles as soon as possible to prevent unsafe conditions EAU23111 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 at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pe...

Page 72: ...ivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur ...

Page 73: ...ition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smo...

Page 74: ...y support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart ...

Page 75: ... 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 battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remo...

Page 76: ... not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan ...

Page 77: ...and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened ...

Page 78: ...turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24202 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 c...

Page 79: ... by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear 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 EAU24360 Front wheel ...

Page 80: ...24851 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that the slot in the speedom eter gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground 5 Install the brake calipers by install ing the bol...

Page 81: ...ha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the wheel axle nut and the brake caliper bolts 2 Remove the cotter pin and then loosen the brake torque rod nut at the brake caliper bracket Tightening torques Wheel axle 65 Nm 6 5 m kgf 47 ft lbf Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft lbf Brake caliper bolt 40 Nm 4 0 m kg...

Page 82: ...not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU25651 To install the rear wheel 1 Install the wheel right wheel axle guide and caliper bracket by in serting the wheel axle from the right hand side 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 28 3 Install the left w...

Page 83: ...shooting charts represent quick and easy procedures 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 inferi or hav...

Page 84: ...ompression 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 Battery ...

Page 85: ...ped 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 the cooling system for l...

Page 86: ... dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on ...

Page 87: ...ter cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mende...

Page 88: ...s chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent 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 ...

Page 89: ...heels are off the ground Alterna tively turn the wheels a little every 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 3...

Page 90: ...ridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 1 95 L 2 06 US qt 1 72 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 19 0 L 5 02 US gal 4 18 Imp gal Fuel reserve amount 3 1 L 0 82 US gal 0 68 I...

Page 91: ...ondition 90 180 kg 198 397 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Sin...

Page 92: ...tion light 12 V 27 W 8 0 W 2 Rear turn signal light 12 V 27 0 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 0 A Headlight fuse 20 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Radiator fan fuse 7 ...

Page 93: ...ntification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and ...

Page 94: ...label is affixed to the frame under the seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5AH1BE0 book Page 2 Thursday May 18 2006 3 45 PM ...

Page 95: ...stigation 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 Tra...

Page 96: ...icle 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 E...

Page 97: ...nder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km o...

Page 98: ...ORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5AH1BE0 book Page 6 Thursday May 18 2006 3 45 PM ...

Page 99: ...CONSUMER INFORMATION 9 7 9 EAU26662 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5AH1BE0 book Page 7 Thursday May 18 2006 3 45 PM ...

Page 100: ...CONSUMER INFORMATION 9 8 9 U5AH1BE0 book Page 8 Thursday May 18 2006 3 45 PM ...

Page 101: ...d repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing ...

Page 102: ...ked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U5AH1BE0 book Page 10 Thursday May 18 2006 3 45 PM ...

Page 103: ... 9 High beam indicator light 3 2 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 14 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model l...

Page 104: ...Troubleshooting charts 6 43 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 37 Turn signal switch 3 5 V Valve clearance 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 33 Wheel front 6 38 Wheel rear 6 40 Wheels 6 24 U5AH1BE0 book Page 2 Thursday May 18 2006 3 45 PM ...

Page 105: ...PRINTED IN JAPAN 2006 05 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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