Yamaha YZFR1V(C) Owner'S Manual Download Page 71 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

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 Yamaha Parts and
Accessories are designed and test-
ed to be compatible with your vehi-
cle. Please consider Genuine
Yamaha Parts and Accessories be-
fore making a purchase. Use of non-
Yamaha-approved accessories or
replacement parts may cause loss of
handling stability and riding safety.
Since Yamaha cannot control the
quality of accessories or parts man-
ufactured by other companies,
Yamaha cannot be held liable for

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

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).

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

U5VY12E0.book Page 23 Thursday, August 4, 2005 4:37 PM

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Summary of Contents for YZFR1V(C)

Page 1: ...5VY 28199 12 YZFR1V C OWNER S MANUAL LIT 11626 19 50 ...

Page 2: ...EAU10041 U5VY12E0 book Page 1 Thursday August 4 2005 4 37 PM ...

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: ...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 WA...

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 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

Page 6: ...tion U S A 1st edition August 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 50 AFFIX DEALER LABEL HERE U5VY12E0 book Page 3 Thursday August 4 2005 4 37 PM ...

Page 7: ...d 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 Cast wheels 6 22 Accessories and replacement parts 6 23 Adjusting the clutch lever free play 6 23 Adjusting th...

Page 8: ...OTORCYCLE 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 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

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: ...ield 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 e...

Page 11: ...ution 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 clearance limit susp...

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: ...NFORMATION 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 U5VY12E0 book Page 5 Thursday August 4 2005 4 37 PM ...

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 U5VY12E0 book Page 6 Thursday August 4 2005 4 37 PM ...

Page 15: ...SAFETY INFORMATION 1 7 1 10 7 8 9 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 3JJ 28446 A1 U5VY12E0 book Page 7 Thursday August 4 2005 4 37 PM ...

Page 16: ...nt fork spring preload adjusting bolt page 3 17 5 Front brake fluid reservoir page 6 25 6 Shock absorber assembly spring preload adjusting ring page 3 18 7 Battery page 6 32 8 Fuel injection system fuse page 6 33 9 Main fuse page 6 33 10 Owner s tool kit page 6 1 11 Engine oil drain bolt page 6 12 12 Engine oil filter cartridge page 6 12 U5VY12E0 book Page 1 Thursday August 4 2005 4 37 PM ...

Page 17: ...oir page 6 25 5 Shock absorber assembly compression damping force adjusting screw page 3 18 6 Engine oil filler cap page 6 12 7 Air filter element page 6 17 8 Engine oil level check window page 6 12 9 Shock absorber assembly rebound damping force adjusting screw page 3 18 10 Coolant reservoir page 6 15 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

Page 18: ...ever page 3 11 2 Left handlebar switches page 3 10 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 5 5 Right handlebar switches page 3 10 6 Throttle grip page 6 19 7 Brake lever page 3 12 U5VY12E0 book Page 3 Thursday August 4 2005 4 37 PM ...

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: ...dicator 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 Eve...

Page 21: ...d 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 d...

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 46 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 46 U5VY12E0 book Page 4 Thursday August 4 2005 4...

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 EAU34552 Multi function m...

Page 24: ...h 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 electri c...

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: ...as 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 electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on and then the right display will indi cate a two digit error code e g 11...

Page 27: ... 1 Push the RESET button to select one of the following indicator light activity settings The indicator light will stay on when activated This setting is selected when the indicator light stays on The indicator light will flash when activated This setting is selected when the indicator light flashes four times per second The indicator light is deacti vated in other words it will not come on or fla...

Page 28: ...ight will remain deactivated 1 Push the RESET button to select the desired engine speed for deac tivating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light bright ness function To adjust the shift timing indicator light brightness 1 Push the RESET button to select the desired indicator light bright ness l...

Page 29: ...is 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 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the ...

Page 30: ... 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 turn the adjusting knob while holding the lever pushed away from the handlebar grip When the de sired position is obtained be sure to set it by aligning a groove on the adjusting knob with the mark on the brake lever 1 Shift p...

Page 31: ... 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 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 sur...

Page 32: ... exhaust system Your Yamaha engine has been de signed to use premium unleaded gaso line with a pump octane number R M 2 of 91 or higher or a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand Use of un leaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that...

Page 33: ...onverter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU33860 Seats Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown...

Page 34: ...ders 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 since the helmet may hit objects causing loss of con trol and possibly an accident To releas...

Page 35: ...ign the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting screw on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in di rection b 1 Spring prel...

Page 36: ...nts 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 EAU33970 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and rebound and compression damping force adjusting screws CAUTION ECA...

Page 37: ...cowling away from the motorcycle as shown 2 To increase the rebound damping force and thereby harden the re bound damping turn the adjusting screw in direction a To decrease 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 Sp...

Page 38: ...ARNING 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 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 op...

Page 39: ...or dam age to the engine If the EXUP system cannot be heard when the main switch is turned on have a Yamaha deal er check it EAU15301 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain sit...

Page 40: ...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 EWA...

Page 41: ...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 42: ...quences 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 w...

Page 43: ...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 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 reserv...

Page 44: ...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 30 Chassis fasteners Make sure that all nuts bolts and screws are properly ti...

Page 45: ... Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 22 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 46: ...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 47: ...on 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 ...

Page 48: ... 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 49: ...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 50: ...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 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

Page 51: ...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 52: ...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 53: ...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 54: ...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 55: ...er 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 t...

Page 56: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U5VY12E0 book Page 8 Thursday August 4 2005 4 37 PM ...

Page 57: ...time 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 U5VY12E0 book Page 9 Thursday August...

Page 58: ...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 59: ... 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 60: ...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 61: ...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 62: ...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 63: ... 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 64: ...ve 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 65: ...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 66: ...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 67: ...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 U5VY12...

Page 68: ...an shift 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 cee...

Page 69: ...al knowl edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires 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 mak...

Page 70: ...rabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or w...

Page 71: ...ssories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha EAU33890 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0...

Page 72: ...llows 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 EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lub...

Page 73: ...e brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommende...

Page 74: ... lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22771 To check the dri...

Page 75: ...arks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the locknuts then the a...

Page 76: ...in dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cab...

Page 77: ...bricated at the intervals specified in the periodic maintenance chart EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U5VY12E0 book Page 29 Thursday August 4...

Page 78: ...t fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition 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 ...

Page 79: ... must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely 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 Yama...

Page 80: ...ds to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water...

Page 81: ...AUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your battery EAU34052 Replacing the fuses The...

Page 82: ...eners by pushing the center in with a screw driver then pulling the fastener out 3 Loosen and remove the quick fas tener screws and then slide the areas of the cowling shown for ward 4 Pull the cowling away from the motorcycle as shown 5 Remove the blown fuse and then install a new fuse of the specified amperage 1 Cowling 1 Quick fastener 1 Quick fastener screw 2 Cowling 1 Fuse box 2 Cowling U5VY1...

Page 83: ... Make sure that the projections are in serted into the slots 9 Install 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 1 Spare fuse 2 Left radiator fan fuse 3 Right radiator fan fuse 4 Backup fuse for odometer and clock 5 Signaling sys...

Page 84: ... touch the bulb until it has cooled down 3 Place a new headlight bulb into po sition 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 oughl...

Page 85: ...ing it counterclockwise 2 Disconnect the headlight coupler 3 Unhook the headlight bulb holder and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take ca...

Page 86: ...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 5 Connect the headlight coupler 6 Install the headlight bulb cover by turning it clockwise 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24180 Tail brake light This model is equipped with an LED type of tail brake light If t...

Page 87: ...ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the lice...

Page 88: ...ner out 3 Remove the socket together with the bulb by pulling it out 4 Remove the defective bulb by pull ing it out 5 Insert a new bulb into the socket 6 Install the socket together with the bulb by pushing it in 7 Install the auxiliary light bulb cover by installing the quick fastener NOTE To install the quick fastener push the center pin out so that it will protrude from the fastener head insert...

Page 89: ... 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 EAU34591 To remove the fr...

Page 90: ...ke calipers by install ing the bolts and then tightening them to the specified torque NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders and reflectors by installing the bolts and nuts 6 Secure the wheel axle by installing the axle bolt and then tightening the axle bolt to the specified torque...

Page 91: ...ebar several times to check for proper fork operation EAU25080 Rear wheel EAU25311 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut Tightening torque Wheel axle pinch bolt 21 Nm 2 1 m kgf 15 ft lbf Tightening torque Wheel axle pinch bolt 21 Nm 2 1 ...

Page 92: ...l CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU25661 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side NOTE Be sure to insert the retainer on the brake caliper bracket into the slot in the swingarm Make sure that the...

Page 93: ...troubleshooting 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...

Page 94: ...mpression 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 T...

Page 95: ...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 96: ...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 97: ...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 98: ...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 99: ... 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 fro...

Page 100: ...cement 3 10 L 3 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 ...

Page 101: ...ZFR1VC 90 200 kg 198 441 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 MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Singl...

Page 102: ...cense plate light 12 V 5 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 Radi...

Page 103: ...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 104: ...n 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 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

Page 105: ...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 106: ...cle 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 Ex...

Page 107: ...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 108: ...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 U5VY12E0 book Page 6 Thursday August 4 2005 4 37 PM ...

Page 109: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5VY12E0 book Page 7 Thursday August 4 2005 4 37 PM ...

Page 110: ...CONSUMER INFORMATION 9 8 9 U5VY12E0 book Page 8 Thursday August 4 2005 4 37 PM ...

Page 111: ... 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 112: ...ed 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 U5VY12E0 book Page 10 Thursday August 4 2005 4 37 PM ...

Page 113: ...am indicator light 3 2 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 22 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 21 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1...

Page 114: ...oubleshooting charts 6 46 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 39 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 32 Wheel front 6 41 Wheel rear 6 43 Wheels 6 22 U5VY12E0 book Page 2 Thursday August 4 2005 4 37 PM ...

Page 115: ...PRINTED IN JAPAN 2005 08 3 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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