Yamaha YZFR1W 2007 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

WARNING

EWA10600

This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.

●

Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.

●

Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
(60 mi) after installing a new tire.

●

The tires must be warmed up
before a high-speed run.

●

Always adjust the tire air pres-
sure according to the operating
conditions.

EAU21960

Cast wheels

To maximize the performance, durabil-
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 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.

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

U4C820E0.book Page 21 Thursday, October 12, 2006 2:14 PM

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Summary of Contents for YZFR1W 2007

Page 1: ...4C8 28199 20 YZF R1W OWNER S MANUAL ...

Page 2: ...U4C820E0 book Page 2 Thursday October 12 2006 2 14 PM ...

Page 3: ...to enjoy all advantages of your YZF R1W The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha deal...

Page 4: ...f you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death ...

Page 5: ...AL 2006 by Yamaha Motor Co Ltd 1st edition October 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U4C820E0 book Page 2 Thursday October 12 2006 2 14 PM ...

Page 6: ...ic maintenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 6 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Coolant 6 13 Replacing the air filter element 6 16 Checking the engine idling speed 6 18 Checking the throttle cable free play 6 18 Valve clearance 6 18 Tires 6 19 Cast wheels 6 21 Adjusting the clutch lever free play 6 21 Adjusting the rear...

Page 7: ...g the motorcycle 6 39 Front wheel 6 40 Rear wheel 6 42 Troubleshooting 6 43 Troubleshooting charts 6 44 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U4C820E0 book Page 2 Thursday October 12 2006 2 14 PM ...

Page 8: ...s 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 moto...

Page 9: ...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 10: ...se 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 clearan...

Page 11: ...quate 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 fa...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U4C820E0 book Page 5 Thursday October 12 2006 2 14 PM ...

Page 13: ...SAFETY INFORMATION 1 6 1 U4C820E0 book Page 6 Thursday October 12 2006 2 14 PM ...

Page 14: ...ast compression damping page 3 22 7 Shock absorber assembly compression damping force adjusting bolt for slow compression damping page 3 22 8 Shock absorber assembly rebound damping force adjusting screw page 3 22 9 Shock absorber assembly spring preload adjusting ring page 3 22 10 Engine oil drain bolt page 6 10 11 Coolant drain bolt page 6 14 12 Engine oil filter cartridge page 6 10 13 Front for...

Page 15: ...page 6 1 4 Passenger seat lock page 3 18 5 Battery page 6 30 6 Air filter element page 6 16 7 Radiator cap page 6 13 8 Coolant reservoir page 6 13 9 Engine oil level check window page 6 10 10 Engine oil filler cap page 6 10 11 Rear brake fluid reservoir page 6 23 U4C820E0 book Page 2 Thursday October 12 2006 2 14 PM ...

Page 16: ... handlebar switches page 3 13 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 7 5 Front brake fluid reservoir page 6 23 6 Right handlebar switches page 3 13 7 Throttle grip page 6 18 8 Brake lever page 3 15 U4C820E0 book Page 3 Thursday October 12 2006 2 14 PM ...

Page 17: ...DIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the co...

Page 18: ...d bow keep it in a safe place and only use it for code re registering EAU10550 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed 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 sta...

Page 19: ...ched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before...

Page 20: ...nction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11361 Fuel level warning light This warning ...

Page 21: ... If this occurs have a Yamaha dealer check the vehicle EAU11423 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool 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 c...

Page 22: ... 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 44 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 44 U4C820E0 book Page 6 Thursday October 12 2006 ...

Page 23: ...n of this indicator light and on how to set it EAU38620 Immobilizer system indicator light 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 When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indic...

Page 24: ...meter 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 cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 13750 r min and above Clock mode Turn the key to ON To set the clo...

Page 25: ... 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 stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stopwa...

Page 26: ...play NOTE Even if the air intake temperature is set to be displayed the coolant temperature 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 di...

Page 27: ...ne or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the right display indicates any error codes note the code number and then have a Yamaha dealer check the vehi cle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as p...

Page 28: ... level 5 Push the SELECT button to con firm the selected brightness level The control mode changes to the shift timing indicator light activity function To set the shift timing indicator light ac tivity function 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 s...

Page 29: ...t the deactivation function to a higher engine speed than for the activation function otherwise the shift timing indicator light 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 ad...

Page 30: ...cle 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 EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12733 Hazard switch With the ...

Page 31: ...tion 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 turn...

Page 32: ...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 33: ...d 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 EAU13390 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 has be...

Page 34: ...revent 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 grass or other materials that easily burn Do not allow the engine to idle too long EAU33861 Seats Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the ...

Page 35: ...e 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 18 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 ...

Page 36: ... ly otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate groove on the ad justing mechanism with the top of th...

Page 37: ...ttings NOTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specific...

Page 38: ...To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the...

Page 39: ... range To obtain a precise adjustment it would be advis able to check the number of clicks or turns of each damping force adjusting mechanism and to modify the specifi cations as necessary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand Rebound damping setting Minimum soft 20 click s in direction b Standard 12 click s in direct...

Page 40: ...trap holders remove the pas senger seat unhook the straps from the hooks and then install the seat with the straps hanging out from under the passenger seat See page 3 18 EAU15281 EXUP system This model is equipped with Yamaha 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 cons...

Page 41: ...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 trans...

Page 42: ... 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 sho...

Page 43: ...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 44: ...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 22 6 23 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 45: ... 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 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tig...

Page 46: ...and up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 25 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11730 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning l...

Page 47: ...OTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION 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...

Page 48: ... it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17081 0 1000 km 0 600 mi Avoid prolonged operation above 6900 r min 1000 1600 km 600 1000 mi Avoid prolonged operation above 8300 r min CAUTI...

Page 49: ... 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 CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U4C820E0 book Page 4 Thursday October 12 2006 2 14 PM ...

Page 50: ...s tool kit The owner s tool kit is located under the passenger seat See page 3 18 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not h...

Page 51: ...READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check op...

Page 52: ...s Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Steering damper Check operation and for oil leakage 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Brake and clutch lever pivot shafts Lubricate with lithium soap based grease 18 Shift pedal rod pivots Lubricate with lithium soap based grease 19 Sidest...

Page 53: ...ca bles Lubricate 30 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damaged parts if necessary 32 Muffler and exhaust pipe Check the screw clamp for looseness 33 EXUP system Check operation cabl...

Page 54: ...r filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U4C820E0 book Page 5 Thursday ...

Page 55: ... this section each time a cowling or panel needs to be re moved and installed EAU42970 Cowlings A and B To remove one of the cowlings 1 Remove the quick fastener screws and the quick fasteners slide the cowling backward and then take it off 1 Panel A 2 Panel C 3 Cowling A 4 Cowling C 1 Panel B 2 Panel D 3 Cowling B 1 Quick fastener screw 1 Cowling A 2 Quick fastener U4C820E0 book Page 6 Thursday O...

Page 56: ... and the quick fastener screws EAU42951 Cowling C To remove the cowling 1 Remove cowling A See page 6 6 2 Remove the bolts and the quick fastener screws 3 Slide the cowling backward to un hook its projections from the slots and then pull the cowling off 1 Cowling B 2 Quick fastener 1 Turn signal light lead coupler 1 Slot 2 Projection 1 Bolt 2 Quick fastener screw 3 Cowling C 1 Cowling C 2 Slot 3 P...

Page 57: ...ge 3 18 2 Remove the screw and then re move the panel as shown To install the panel 1 Place the panel in its original posi tion and then install the screw 2 Install the rider seat EAU36630 Panels C and D 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 a...

Page 58: ...gs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark pl...

Page 59: ...eplaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it...

Page 60: ...replaced 5 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 6 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 7 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil...

Page 61: ...dle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 11 Turn ...

Page 62: ...l ant reservoir NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove cowl ing B See page 6 6 4 Remove the reservoir cap add coolant to the maximum level mark and then install the reservoir cap CAUTION ECA10471 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water ...

Page 63: ...or further instructions EAU42980 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove cowlings B and C See page 6 6 3 Place a container under the engine to collect the used coolant 4 Remove the radiator cap WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Remove the coolant drain bolt to drain the cooling sys...

Page 64: ...ater has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 13 Install the radiator cap start the engine let it idle for several min utes and then turn it off 14 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches...

Page 65: ...t 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 hoses may come loose which could cause fuel leakage 5 Remove the air filter case cover by removing the screws CAUTION ECA12880 When removing the air filter ...

Page 66: ... the screws 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 that the fuel hoses are properly connected and routed and are not pinched Be sure to place the...

Page 67: ...rottle EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check 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 val...

Page 68: ...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 69: ...ocal regulations 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 make sure that ...

Page 70: ...ecked 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 wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a shor...

Page 71: ...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 lubrication chart EAU43060 Front brake...

Page 72: ... the 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 recomme...

Page 73: ...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 EAU22772 To check the driv...

Page 74: ...rks 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 ax...

Page 75: ...ents 2 Wipe the drive chain 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 EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each rid...

Page 76: ...ricated 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 U4C820E0 book Page 27 Thursday October 1...

Page 77: ...metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grea...

Page 78: ... check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubricati...

Page 79: ...3441 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrica...

Page 80: ...IS 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 charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make su...

Page 81: ...he fuel injection system fuse is locat ed under the fuel tank and can be ac cessed as follows 1 Lift the fuel tank See page 6 16 2 Pull up the rubber damper as shown To access the fuse box The fuse box which contains the fuses for the individual circuits is located be hind cowling A To access the fuse box remove cowl ing A See page 6 6 1 ECU 1 Main fuse 1 Rubber damper 1 Fuel injection system fuse...

Page 82: ...ON and turn on the electrical circuit in question to check if the device operates 1 Fuse box 1 Turn signal light fuse 2 Headlight fuse 3 Ignition fuse 4 Signaling system fuse 5 ETV electric throttle valve fuse 6 Backup fuse for odometer clock and immo bilizer system 7 Right radiator fan fuse 8 Left radiator fan fuse 9 Spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling syst...

Page 83: ...ows To replace a high beam headlight bulb 1 Remove panel C if replacing the left headlight bulb or panel D if re placing the right headlight bulb See page 6 6 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 High beam headlight bulb 2 Low beam headlight bulb 1 Headlight bulb cover 2 Headlight coupler 1 Headlig...

Page 84: ...hor 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 5 Install the headlight bulb cover and then connect the coupler 6 Install the panel 7 Have a Yamaha dealer adjust the headlight beam...

Page 85: ...wise 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 to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Connect the headlight...

Page 86: ... 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 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...

Page 87: ...the left auxiliary light bulb or panel D if replacing the right auxiliary light bulb See page 6 6 2 Remove the auxiliary light bulb cover by removing the quick fas tener NOTE Remove the quick fastener by pushing the center pin in with a screwdriver then pulling the fastener 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 ne...

Page 88: ...he 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 motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear w...

Page 89: ...ake 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 CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut EAU33932 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that...

Page 90: ...9 Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle 10 Tighten wheel axle pinch bolt D and then tighten pinch bolt C to the specified torque 11 Retighten pinch bolt D to the spec ified torque 12 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bolt 3...

Page 91: ...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 disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forc...

Page 92: ...oblem 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 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 pr...

Page 93: ...There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric start...

Page 94: ...d press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for lea...

Page 95: ...the muffler outlets with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and whee...

Page 96: ... a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely co...

Page 97: ...is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA11130 Make sure that there is no oil or wax on the brakes or ti...

Page 98: ...e electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the ...

Page 99: ...ilter cartridge replacement 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 ...

Page 100: ... 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 Single disc brake Operation R...

Page 101: ...t 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 Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 7 5 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Turn signal...

Page 102: ...ification 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 may be used to register your mot...

Page 103: ...for Australia TAMPERING WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in u...

Page 104: ... 4 Horn switch 3 14 I Identification numbers 9 1 Ignition circuit cut off system 3 25 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 37 Luggage strap holders 3 24 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Multi function meter un...

Page 105: ...Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 37 Turn signal switch 3 14 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheel front 6 40 Wheel rear 6 42 Wheels 6 21 U4C820E0 book Page 2 Thursday October 12 2006 2 14 PM ...

Page 106: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 107: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 108: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 10 0 6 1 CR E ...

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