Yamaha YZFR1W(C) Owner'S Manual Download Page 68 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6

CAUTION:

ECA12880

When removing the air filter case
cover, be careful not to allow foreign
objects to drop into the air intake
manifold.

6. Pull the air filter element out.

7. Install a new air filter element by fit-

ting the projections on the element
into the slots in the air filter case.

CAUTION:

ECA10480

●

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

●

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

8. Install the air filter case cover by in-

stalling 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.

1. Screw
2. Air filter case cover

1. Air filter element
2. Air intake manifold

1. Projection
2. Slot

U4C810E0.book Page 20 Wednesday, September 27, 2006 3:06 PM

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Summary of Contents for YZFR1W(C)

Page 1: ...4C8 28199 10 YZFR1W C OWNER S MANUAL LIT 11626 20 53 ...

Page 2: ...EAU10041 U4C810E0 book Page 1 Wednesday September 27 2006 3 06 PM ...

Page 3: ...le 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 stand...

Page 4: ...sult 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 WARNI...

Page 5: ...HNIQUES 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 U4C810E0 book Page 2 Wednesday September 27 2006 3 06 PM ...

Page 6: ... U S A 1st edition September 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 20 53 AFFIX DEALER LABEL HERE U4C810E0 book Page 3 Wednesday September 27 2006 3 06 PM ...

Page 7: ...tenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 9 Checking the spark plugs 6 12 Canister for California only 6 13 Engine oil and oil filter cartridge 6 13 Coolant 6 16 Replacing the air filter element 6 19 Checking the throttle cable free play 6 21 Valve clearance 6 21 Tires 6 22 Cast wheels 6 24 Accessories and replacement parts 6 24 Adjusting the clutch lever free...

Page 8: ...oubleshooting charts 6 47 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 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 U4C810E0 book Page 2 Wednes...

Page 9: ... 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 motor...

Page 10: ...d 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 exha...

Page 11: ...e 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 clearanc...

Page 12: ...uate 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 fal...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U4C810E0 book Page 5 Wednesday September 27 2006 3 06 PM ...

Page 14: ...asoline or solvent will damage windshield Use neutral detergent 5JW 00 California only California only California only HOWTO LAYOUT FUEL HOSES 1 2 3 4 FUEL DELIVERY FUEL PUMP FUEL FILTER PRESS REGULATOR 2C0 2178A 00 FUEL TANK U4C810E0 book Page 6 Wednesday September 27 2006 3 06 PM ...

Page 15: ...E READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protectibe clothing PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 3JJ 28446 A1 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 U4C810E0 book Page 7 Wednesday September 27 2006 3 06 PM ...

Page 16: ...t compression damping page 3 19 7 Shock absorber assembly compression damping force adjusting bolt for slow compression damping page 3 19 8 Shock absorber assembly rebound damping force adjusting screw page 3 19 9 Shock absorber assembly spring preload adjusting ring page 3 19 10 Engine oil drain bolt page 6 13 11 Coolant drain bolt page 6 17 12 Engine oil filter cartridge page 6 13 13 Front fork ...

Page 17: ...age 6 1 4 Passenger seat lock page 3 15 5 Battery page 6 34 6 Air filter element page 6 19 7 Radiator cap page 6 16 8 Coolant reservoir page 6 16 9 Engine oil level check window page 6 13 10 Engine oil filler cap page 6 13 11 Rear brake fluid reservoir page 6 27 U4C810E0 book Page 2 Wednesday September 27 2006 3 06 PM ...

Page 18: ...handlebar switches page 3 11 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 5 5 Front brake fluid reservoir page 6 27 6 Right handlebar switches page 3 11 7 Throttle grip page 6 21 8 Brake lever page 3 12 U4C810E0 book Page 3 Wednesday September 27 2006 3 06 PM ...

Page 19: ...ine 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 wa...

Page 20: ...ator 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 i...

Page 21: ...hen 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 deal...

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 47 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 47 U4C810E0 book Page 4 Wednesday September 27 200...

Page 23: ...form 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 EAU34554 Multi function met...

Page 24: ...he 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 cal ...

Page 25: ...u 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 stopwatch ...

Page 26: ...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 diagnosis devices Th...

Page 27: ...elect the engine speed at which the indi cator light will be deactivated Shift timing indicator light bright ness 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 mete...

Page 28: ...the SELECT button to con firm the selected engine speed 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...

Page 29: ...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 5 1 for starting instruc tions prior to starting the engine EAU41700 The en...

Page 30: ...ion 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 31: ...e 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 tan...

Page 32: ...void 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 has...

Page 33: ...aust 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 grass ...

Page 34: ...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 since the helmet may hi...

Page 35: ...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 the...

Page 36: ...ings 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 specificat...

Page 37: ... 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 a...

Page 38: ...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 directi...

Page 39: ...rap 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 15 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 const...

Page 40: ...he 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 41: ...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 shou...

Page 42: ...nces 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 work...

Page 43: ... or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 26 6 27 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 reservoir...

Page 44: ...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 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tigh...

Page 45: ...efore 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 l...

Page 46: ... 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 which...

Page 47: ...EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for...

Page 48: ...the vehi cle NOTE During and after the engine break in period the exhaust heat may cause discoloration of the exhaust pipe but this is normal 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 s...

Page 49: ...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 VICE...

Page 50: ...sive 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 U4C810E0 book Page 2 Wednesday September 27 2006 3 06 PM ...

Page 51: ... Spark plugs Check 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 Adjust synchronization 6 Exhaust system Check for leakage Tighten if necessary Replace g...

Page 52: ...tch 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 Re...

Page 53: ...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 Shift pedal rod piv ots Apply lithium soap based grease all purpose grease lightly 16 Sidestand pivot Check operation Apply lithium soap based...

Page 54: ...stem Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 24 EXUP system Check operation cable free play and pulley position Every 12000 mi 19000 km 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS...

Page 55: ...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 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the ...

Page 56: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U4C810E0 book Page 8 Wednesday September 27 2006 3 06 PM ...

Page 57: ...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 U4C810E0 book Page 9 Wednesday S...

Page 58: ...and the quick fastener screws EAU42951 Cowling C To remove the cowling 1 Remove cowling A See page 6 9 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 Pr...

Page 59: ...e 3 15 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 an...

Page 60: ...s 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 plu...

Page 61: ...g this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Make sure that the canister breath er is not blocked and if necessary clean it EAU19911 Engine oil and oil filter car tridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replace...

Page 62: ...e an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 5 7 if the oil filter cartridge is not being 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 ca...

Page 63: ...dditives 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 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 ...

Page 64: ...chart EAU42990 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the cool...

Page 65: ...he radiator cap when the engine is hot 5 Install the cowling NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 47 for 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 9 3 Place a cont...

Page 66: ...t available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with cool ant as soon as possible other wise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of 1 Coolant dra...

Page 67: ...960 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 3 15 2 Remove panels A and B See page 6 9 3 Remove the fuel tank bolts 4 Lift the front of the fuel tank and the...

Page 68: ...r filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by in stalling 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...

Page 69: ...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 valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Fuel tank b...

Page 70: ...t 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 m...

Page 71: ...ith 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 the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and ...

Page 72: ...he 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 E...

Page 73: ...ch 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 ...

Page 74: ...rication chart EAU43060 Front brake pads The front brake calipers are equipped with two sets of brake pads Each front brake pad is provided with one or two wear indicators which allow you to check the brake pad wear with out having 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...

Page 75: ...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 and ...

Page 76: ...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 the ...

Page 77: ...als 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 no...

Page 78: ...s 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 a...

Page 79: ...ver pivots should be lu bricated if necessary EAU43070 Checking and lubricating the shift pedal The operation of the shift pedal should be checked before each ride and the shift pedal rod pivots should be lubricat ed if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U4C810E0 book Page 31 Wednesday Se...

Page 80: ...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 fa...

Page 81: ...st 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 Yamaha ...

Page 82: ...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 IN...

Page 83: ...e properly con nected to the battery terminals CAUTION 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 char...

Page 84: ...tains the fuses for the individual circuits is located be hind cowling A To access the fuse box remove cowl ing A See page 6 9 1 Main fuse 1 Rubber damper 1 Fuel injection system fuse 2 Fuel injection system spare fuse 1 Fuse box 1 Headlight fuse 2 Ignition fuse 3 Signaling system fuse 4 ETV electric throttle valve fuse 5 Backup fuse for odometer clock and immo bilizer system 6 Right radiator fan ...

Page 85: ... again have a Yamaha dealer check the electrical system EAU42930 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 Remove panel C if replacing the left headlight bulb or panel D if re placing the right headlight bulb See page 6 9 2 Disconnect the headlight coupler and then remove...

Page 86: ... 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 Install the headlight bulb cover and then connect the co...

Page 87: ... 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 to...

Page 88: ...ght 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 overtighten ...

Page 89: ...AU33910 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 C if replacing the left auxiliary light bulb or panel D 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 cen...

Page 90: ... 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 m...

Page 91: ... 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 42 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 w...

Page 92: ...olt 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 of ...

Page 93: ...ve 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 dis...

Page 94: ...o 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 sel...

Page 95: ...ere 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 starter...

Page 96: ... 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 leak...

Page 97: ...he 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 wheel...

Page 98: ... 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 corr...

Page 99: ... 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 tire...

Page 100: ... 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 e...

Page 101: ...t 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 2 L 0 85 US gal 0...

Page 102: ...Pa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 196 kg 198 432 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 R...

Page 103: ... 12 V 5 0 W 2 License 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 7 5 A Ignition f...

Page 104: ...fication 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 may...

Page 105: ...his 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 U4C810E0 book Page 2 Wednesday September 27 2006 3 06 PM ...

Page 106: ... 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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh ...

Page 107: ... 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 Exhau...

Page 108: ...r 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 4...

Page 109: ...ATION 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 U4C810E0 book Page 6 Wednesday September 27 2006 3 06 PM ...

Page 110: ...rranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha moto...

Page 111: ...ter date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warrant...

Page 112: ...epairs 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 pho...

Page 113: ...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 U4C810E0 book Page 10 Wednesday September 27 2006 3 06 PM ...

Page 114: ...ight 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 41 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 Maintenance r...

Page 115: ... 47 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 40 Turn signal switch 3 11 V Valve clearance 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 34 Wheel front 6 43 Wheel rear 6 45 Wheels 6 24 U4C810E0 book Page 2 Wednesday September 27 2006 3 06 PM ...

Page 116: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 117: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 118: ...PRINTED IN JAPAN 2006 10 4 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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