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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

any consequences caused by the
use of items which have not been
approved by Yamaha.

EAU33890

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.
To increase the clutch lever free play,
turn the adjusting bolt at the clutch lever
in direction (a). To decrease the clutch
lever free play, turn the adjusting bolt in
direction (b).

NOTE:

If the specified clutch lever free play
cannot be obtained as described
above, proceed as follows.

1. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loos-
en the clutch cable.

2. Loosen the locknut at the crank-

case.

3. To increase the clutch lever free

play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).

4. Tighten the locknut.

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

U4B110E0.book Page 23 Friday, October 14, 2005 10:55 AM

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Summary of Contents for YZFR1LEC

Page 1: ...4B1 28199 10 YZFR1LEV C OWNER S MANUAL LIT 11626 19 75 ...

Page 2: ...EAU10041 U4B110E0 book Page 1 Friday October 14 2005 10 55 AM ...

Page 3: ...cycle 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 st...

Page 4: ...onsult 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 WAR...

Page 5: ...ECHNIQUES 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 U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 6: ...tion U S A 1st edition October 2005 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 19 75 AFFIX DEALER LABEL HERE U4B110E0 book Page 3 Friday October 14 2005 10 55 AM ...

Page 7: ...maintenance and lubrication chart 6 4 Removing and installing panels 6 9 Checking the spark plugs 6 10 Canister for California only 6 11 Engine oil and oil filter cartridge 6 12 Coolant 6 15 Replacing the air filter element 6 17 Checking the throttle cable free play 6 19 Valve clearance 6 19 Tires 6 20 Forged wheels 6 22 Accessories and replacement parts 6 22 Adjusting the clutch lever free play 6...

Page 8: ...TORCYCLE 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 WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 9: ...ts 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 mot...

Page 10: ...eld 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 ex...

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 cleara...

Page 12: ...equate 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 f...

Page 13: ...FORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 4 5 6 7 8 2 3 1 9 10 U4B110E0 book Page 5 Friday October 14 2005 10 55 AM ...

Page 14: ... UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 5PW 2415E 11 HOWTO LAYOUT FUEL HOSES 5VY 2178A 00 1 2 3 4 FUEL DELIVERY FUEL TANK FUEL PUMP FUEL FILTER PRESS REGULATOR California only California only EMISSION HOSE ROUTING 1 2 3 4 THROTTLE BODY CHARCOAL CANISTER FUEL TANK ATMOSPHERE 5SL 21686 00 California only U4B110E0 book Page 6 Friday October 14 2005 10 55 AM ...

Page 15: ...SAFETY INFORMATION 1 7 1 10 7 8 9 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 3JJ 28446 A1 U4B110E0 book Page 7 Friday October 14 2005 10 55 AM ...

Page 16: ...ob page 3 19 6 Shock absorber assembly compression damping force adjusting bolt for fast compression damping page 3 19 7 Shock absorber assembly compression damping force adjusting screw for slow compression damping page 3 19 8 Battery page 6 32 9 Fuel injection system fuse page 6 33 10 Main fuse page 6 33 11 Owner s tool kit page 6 1 12 Engine oil drain bolt page 6 12 13 Engine oil filter cartrid...

Page 17: ... 5 Engine oil filler cap page 6 12 6 Air filter element page 6 17 7 Front fork compression damping force adjusting bolt page 3 17 8 Engine oil level check window page 6 12 9 Seat height adjusting bolt page 3 22 10 Shock absorber assembly rebound damping force adjusting screw page 3 19 11 Coolant reservoir page 6 15 U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 18: ...ever page 3 12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 5 5 Right handlebar switches page 3 11 6 Throttle grip page 6 19 7 Brake lever page 3 12 U4B110E0 book Page 3 Friday October 14 2005 10 55 AM ...

Page 19: ...ngine can be started The key cannot be re moved NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 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 ...

Page 20: ...icator light This indicator light comes on when the high beam of the headlight is switched on EAU11250 Oil level warning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked by turning 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 electrical cir cuit NOTE Even...

Page 21: ... then go off have a Yamaha dealer check the elec trical circuit NOTE This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit is defective the following cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times and then go off for 3 0 seconds If this occurs have a Yamaha de...

Page 22: ...K Go ahead with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 45 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 45 U4B110E0 book Page 4 Friday October 14 2005 1...

Page 23: ...inform the rider when it is time to shift to the next higher gear The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit See page 3 5 for a detailed expla nation of the function of this indicator light and on how to set it EAU34553 Multi function m...

Page 24: ... switch the speedometer and odometer tripmeter displays be tween kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the ele...

Page 25: ...you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SE LECT button The stopwatch digits will start flashing Release the SE LECT button and then push it again for a few seconds until the stopwatc...

Page 26: ...emperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed before the temperature Self diagnosis devices This model is equipped with a self diag nosis device for various ...

Page 27: ...ss This function allows you to adjust the brightness of the indicator light to suit your preference NOTE In this mode the right display shows the current setting for each function except the shift timing indicator light activity function To adjust the brightness of the multi function meter displays and tachometer 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to ON and the...

Page 28: ...peed The control mode changes to the shift timing indicator light deactiva tion function To set the shift timing indicator light de activation function NOTE The shift timing indicator light de activation function can be set be tween 7000 r min and 15000 r min From 7000 r min to 12000 r min the indicator light can be set in in crements of 500 r min From 12000 r min to 15000 r min the in dicator lig...

Page 29: ... has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 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 vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See ...

Page 30: ...ation with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU33850 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting knob To adjust the dis tance between the brake lever and the handlebar grip tur...

Page 31: ...the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover 1 Brake pedal 1 Fuel t...

Page 32: ... Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13380 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine h...

Page 33: ...xhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as gras...

Page 34: ...he key NOTE Make sure that the seats are properly secured before riding EAU33870 Helmet holders The helmet holders are located on the bottom of the passenger seat To secure a helmet to a helmet hold er 1 Remove the passenger seat See page 3 15 2 Attach the helmet to a helmet hold er and then securely install the passenger seat WARNING EWA11040 Never ride with a helmet attached to a helmet holder s...

Page 35: ... the spring preload the adjuster has to be set to the standard position first To find the standard position start by turning the adjusting bolt on each fork leg in direction a until it stops then check the alignment mark position a If the alignment mark on the ad justing bolt is positioned past the alignment mark on the front fork cap as shown in illustration A turn the adjusting bolt in direction...

Page 36: ... the adjusting bolt in direction b from the standard position making sure to turn the bolt complete turns so that the alignment marks match Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting bolt on each fork leg in direction a To decrease the re bound damping force and thereby soft en the rebound damping turn the adjusting bolt o...

Page 37: ...orce ad justing mechanism and to modify the specifications as necessary EAU39270 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing knob and a rebound damping force adjusting screw It is also equipped with a compression damping force adjusting bolt for fast compression damping and a compression damping force ad justing screw for slow com...

Page 38: ...ecrease the rebound damping force and thereby soften the rebound damp ing turn the adjusting screw in di rection b 3 Place the cowling in its original po sition install and tighten the quick fastener screw and then install the bolt 1 Spring preload adjusting knob Spring preload setting Minimum soft 0 turn s in direction b Standard 6 turn s in direction b Maximum hard 20 turn s in direction b With ...

Page 39: ...st ment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to mod ify the specifications as necessary 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 The manufacturer cannot be held re sponsible for property damage or per...

Page 40: ...ener screw and then pull the cowling away from the motorcycle 2 Loosen the relay arm connecting rod bolts 3 To increase the seat height turn the adjusting bolt in direction a To decrease the seat height turn the adjusting bolt in direction b NOTE The longer distance A is the lower the seat height The shorter dis tance A is the higher the seat height The minimum seat height is the standard setting ...

Page 41: ...amaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor CAUTION ECA10191 The EXUP system has been set and extensively tested at the Yamaha factory Changing these settings without sufficien...

Page 42: ... the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tran...

Page 43: ...r 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 sh...

Page 44: ...uences 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 wo...

Page 45: ...ft 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 24 6 25 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 reservo...

Page 46: ...2 Shift pedal Make sure that operation is smooth Correct if necessary Brake pedal Make sure that operation is smooth Correct if necessary Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and screws are properly ti...

Page 47: ... Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 24 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11830 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light Fuel level warning...

Page 48: ...ON ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train whi...

Page 49: ...n 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 f...

Page 50: ... the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 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 or on soft ground otherwise the vehicle may overturn CAUT...

Page 51: ...D TO EMISSIONS 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 VI...

Page 52: ...essive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes WARNING EWA12371 Do not touch either muffler bracket located under the muffler bracket covers until the exhaust system has cooled 1 Muffler bracket cover 2 Muffler bracket U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 53: ...heck condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system Check for leakage Tighten if n...

Page 54: ...lutch 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 ...

Page 55: ...mi 25000 km or 24 months Repack 12 Steering damper Check operation and for oil leak age 13 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 14 Brake and clutch le ver 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 switch Check operation ...

Page 56: ...or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 EXUP system Check operation cable free play and pulley position Every 12000 mi 19000 km 24 Front and rear brake switches Check operation 25 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4...

Page 57: ...r disassembling the brake master cylinders 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 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate th...

Page 58: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U4B110E0 book Page 8 Friday October 14 2005 10 55 AM ...

Page 59: ...ime a panel needs to be removed and installed EAU36630 Panels A and C To remove one of the panels Remove the screw and the quick fas tener and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw and the quick fastener 1 Panel A 2 Panel B 1 Panel C 2 Panel D 1 Screw 2 Panel A 3 Quick fastener U4B110E0 book Page 9 Friday October 1...

Page 60: ...rdance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a d...

Page 61: ... ignition coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU19681 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor...

Page 62: ...the crankcase NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level as fol lows a Fit the rubber protector on the special wrench NOTE The special wrench and rubber protec tor are included in the owner s tool kit b Remove the engine oil filler cap...

Page 63: ...e to collect the used oil 5 Remove the engine oil filler cap with the special wrench 6 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 7 9 if the oil filter cartridge is not being replaced 7 Remove the oil filter cartridge with an oil filter wrench 1 Cowling 1 Quick fastener screw 2 Bolt 3 Cowling 1 Cowling 2 Projection 1 Engine oil drain bolt 1 Oil filter wren...

Page 64: ...the oil filler cap with the special wrench CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er 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 1 ...

Page 65: ... position 15 Install and tighten the quick fasten er screws and then install the bolt EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU34011 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The coola...

Page 66: ...e a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 4 Install the coolant reservoir cap and then install the brake fluid res ervoir bracket bolt NOTE The radiator fans are automatically switched on or off according to the coolant ...

Page 67: ...tly if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 3 15 2 Remove panels B and D See page 6 9 3 Remove the bolts 4 Lift the front of the fuel tank and then tilt it back and away from the air filter case Do not disconnect 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 ho...

Page 68: ...sively worn 8 Install the air filter case cover by in stalling the screws and then install the rubber cap 9 Place the fuel tank in its original position and then install the bolts WARNING EWA12380 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 Have a Yamaha dealer replace the hose other wise fuel may leak Make sure ...

Page 69: ...eck the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 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 by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Throttle cable free play U4B110...

Page 70: ...ift Securely pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the...

Page 71: ...s should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation du...

Page 72: ...balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is...

Page 73: ...utch lever free play turn the adjusting bolt in direction b NOTE If the specified clutch lever free play cannot be obtained as described above proceed as follows 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Loosen the locknut at the crank case 3 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch l...

Page 74: ...fied in the periodic maintenance and lubrication chart EAU36890 Front brake pads Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches the brake ...

Page 75: ...e recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid an...

Page 76: ...e on the side stand NOTE When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the 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 EAU34311 To adjust th...

Page 77: ...rvals specified 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 CAUTION ECA10581 The drive 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 ...

Page 78: ... not move smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged 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 ad...

Page 79: ...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 WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soa...

Page 80: ... 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 smoothly CAUTION...

Page 81: ... 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 I...

Page 82: ... water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully ...

Page 83: ... box which contains the fuses for the individual circuits is located be hind the cowling shown If a fuse is blown replace it as follows NOTE Include steps 2 4 and 8 9 only for the fuses in the fuse box 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the quick fasteners by pushing the center in with a screw driver then pulling the fastener out 1 Main fuse 2 Fuel injec...

Page 84: ... motorcycle as shown 5 Remove the blown fuse and then install a new fuse of the specified amperage 1 Quick fastener 1 Quick fastener screw 2 Cowling 1 Fuse box 2 Cowling 1 Spare fuse 2 Left radiator fan fuse 3 Right radiator fan fuse 4 Backup fuse for odometer and clock 5 Signaling system fuse 6 Ignition fuse 7 Headlight fuse U4B110E0 book Page 34 Friday October 14 2005 10 55 AM ...

Page 85: ... the quick fasteners NOTE To install a quick fastener push its pin back so that it protrudes from the fas tener head then insert the fastener and push the protruding pin in until it is flush with the fastener head EAU33900 Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows To replace a high beam headlight bulb 1 Disconn...

Page 86: ...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 with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 4 Install the headlight bulb cover and then co...

Page 87: ...ow 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 with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers ...

Page 88: ...light does not come on have a Yamaha dealer check it 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 clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighte...

Page 89: ... EAU33910 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove panel A if replacing the left auxiliary light bulb or panel C if replacing the right auxiliary light bulb See page 6 9 2 Remove the auxiliary light bulb cover by removing the quick fas tener NOTE Remove the quick fastener by pushing the c...

Page 90: ...ed with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a...

Page 91: ...he wheel axle pinch bolts the axle bolt and then the brake caliper bolts 2 Lift the front wheel off the ground according to the procedure on page 6 40 3 Remove the brake hose holder and reflector on each side by re moving the bolt and nut 4 Remove the brake caliper on each side by removing the bolts 5 Remove the axle bolt push the wheel axle out from the left side and then remove the wheel 1 Front...

Page 92: ... bolt and then tightening the axle bolt to the specified torque NOTE While tightening the axle bolt hold the wheel axle with a 19 mm hexagon wrench to keep it from turning 7 Tighten wheel axle pinch bolt B and then tighten pinch bolt A to the specified torque 8 Retighten pinch bolt B to the spec ified torque 9 Tap the outer side of the right fork leg with a rubber mallet to align it with the end o...

Page 93: ...move the axle nut 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a and push the wheel forward 6 Remove the drive chain from the rear sprocket NOTE If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be d...

Page 94: ... to the speci fied torque EAU25870 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 troubleshooting charts represent quick and easy procedures for checking these vital systems your s...

Page 95: ...pression 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 Th...

Page 96: ...hissing 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 th...

Page 97: ...o 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 other plastic parts and the muf fler Use only a soft clean cloth or sponge with mild detergent and water to clean plastic How ever if the muffler cannot be th...

Page 98: ...drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces except the tita nium muffler to prevent corrosion Cleaning the titanium muffler This model is equipped with a titanium muffler which requires the following special care Use only a soft clean cloth or sponge with mild detergent and water to clean the titanium muffler However if the muf...

Page 99: ...ny excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26201 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA1081...

Page 100: ...ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from...

Page 101: ...28 US qt 2 73 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 76 L 2 92 US qt 2 43 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal...

Page 102: ... 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 Forged wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Forged wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Re...

Page 103: ...0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Fu...

Page 104: ...tification 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 m...

Page 105: ... this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer WARNING EWA12371 Do not touch either muffler bracket located under the muffler bracket covers until the exhaust system has cooled 1 Model label 1 Muffler bracket cover 2 Muffler bracket U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 106: ...tigation 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 Tran...

Page 107: ...le 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 Exh...

Page 108: ...der 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 or...

Page 109: ...RMATION 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 U4B110E0 book Page 6 Friday October 14 2005 10 55 AM ...

Page 110: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U4B110E0 book Page 7 Friday October 14 2005 10 55 AM ...

Page 111: ...CONSUMER INFORMATION 9 8 9 U4B110E0 book Page 8 Friday October 14 2005 10 55 AM ...

Page 112: ... 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 p...

Page 113: ...d 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 U4B110E0 book Page 10 Friday October 14 2005 10 55 AM ...

Page 114: ... 1 Ignition circuit cut off system 3 24 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 39 Luggage strap holders 3 23 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 label 9 2 Multi function meter unit ...

Page 115: ...s 3 2 Turn signal light bulb replacing 6 38 Turn signal switch 3 11 V Valve clearance 6 19 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheel front 6 41 Wheel rear 6 43 Wheels 6 22 U4B110E0 book Page 2 Friday October 14 2005 10 55 AM ...

Page 116: ...PRINTED IN JAPAN 2005 11 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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