Yamaha YZFR6V(C) Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

EAU36762

Air filter element

The air filter element must be replaced
at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the air
filter element.

EAU21381

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 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

U2C010E0.book Page 21 Wednesday, October 26, 2005 10:19 AM

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Summary of Contents for YZFR6V(C)

Page 1: ...2C0 28199 10 YZFR6V C OWNER S MANUAL LIT 11626 19 78 ...

Page 2: ...EAU10041 U2C010E0 book Page 1 Wednesday October 26 2005 10 19 AM ...

Page 3: ...cle 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 stan...

Page 4: ...nsult 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 WARN...

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 U2C010E0 book Page 2 Wednesday October 26 2005 10 19 AM ...

Page 6: ...on U S A 1st edition October 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 19 78 AFFIX DEALER LABEL HERE U2C010E0 book Page 3 Wednesday October 26 2005 10 19 AM ...

Page 7: ... maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 9 Checking the spark plugs 6 13 Canister for California only 6 14 Engine oil and oil filter cartridge 6 14 Coolant 6 17 Air filter element 6 21 Checking the throttle cable free play 6 21 Valve clearance 6 21 Tires 6 22 Cast wheels 6 24 Accessories and replacement parts 6 25 Adjusting the clutch lever free play 6 2...

Page 8: ... 44 Troubleshooting charts 6 45 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U2C010E0 book Page 2 Wednesday October 26 200...

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: ...ld 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 exh...

Page 11: ...aution 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 sus...

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 U2C010E0 book Page 5 Wednesday October 26 2005 10 19 AM ...

Page 14: ...gasoline 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 U2C010E0 book Page 6 Wednesday October 26 2005 10 19 AM ...

Page 15: ... 10 5 PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 5PW 2415E 11 WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 U2C010E0 book Page 7 Wednesday October 26 2005 10 19 AM ...

Page 16: ...hock absorber assembly compression damping force adjusting screw for slow compression damping page 3 20 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 20 9 Shift pedal page 3 12 10 Engine oil drain bolt page 6 14 11 Engine oil filter cartridge page 6 14 12 Front fork compression damping force adjusting bolt for fast compres sion damping page 3 17...

Page 17: ...se page 6 36 6 Battery page 6 35 7 Air filter element page 6 21 8 Front brake fluid reservoir page 6 27 9 Radiator cap page 6 17 10 Coolant reservoir page 6 17 11 Engine oil filler cap page 6 14 12 Coolant drain bolt page 6 18 13 Dipstick page 6 14 14 Brake pedal page 3 13 15 Rear brake fluid reservoir page 6 27 U2C010E0 book Page 2 Wednesday October 26 2005 10 19 AM ...

Page 18: ...er page 3 12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 5 5 Right handlebar switches page 3 11 6 Brake lever page 3 12 7 Throttle grip page 6 21 U2C010E0 book Page 3 Wednesday October 26 2005 10 19 AM ...

Page 19: ...gine can be started The key cannot be re moved NOTE The headlight comes on automatically when the engine is started and stays 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: ...cator light This indicator light comes on when the high beam of the headlight is switched on EAU11250 Oil level warning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit NOTE Even ...

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

Page 22: ...Go ahead with riding 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 45 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 45 U2C010E0 book Page 4 Wednesday October 26 2005 ...

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 EAU39250 Multi function met...

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

Page 25: ...ou 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: ...perature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed before the temperature Self diagnosis devices This model is equipped with a self diag nosis device for various el...

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

Page 28: ...ed 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 10000 r min and 18000 r min From 10000 r min to 13000 r min the indicator light can be set in increments of 500 r min From 13000 r min to 18000 r min the in dicator ligh...

Page 29: ...as re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See pa...

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: ...he 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 ta...

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

Page 33: ...haust 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: ... 2 Remove the key NOTE Make sure that the seats are properly secured before riding EAU39072 Helmet holding cable A helmet holding cable is provided in the owner s tool kit to secure two hel mets to the helmet cable holder equipped on the bottom of the passen ger seat To secure a helmet with the helmet holding cable 1 Remove the passenger seat See page 3 15 2 Clip the middle snap hook of the cable ...

Page 35: ...d then remove the cable from the helmet strap buck le 3 Install the passenger seat EAU38941 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting bolts WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload To in...

Page 36: ...ing To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting bolt on each fork leg in direction b 1 Current setting 2 Front fork collar Spring preload setting Minimum soft 0 Standard 1 Maximum hard 5 1 Rebound ...

Page 37: ...nd the maximum or minimum settings 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 mechanis...

Page 38: ...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 adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b 1 Spring pr...

Page 39: ...ent 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 WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or person...

Page 40: ...ealer service the shock absorber EAU38961 Luggage strap holders There are six luggage strap holders four on the bottom of the passenger seat and one on each passenger foot rest To use the luggage strap holders on the passenger seat remove the passenger 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 1 Luggage s...

Page 41: ... 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 situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the sid...

Page 42: ... 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 EWA10250 If a malfunction is noted have a Y...

Page 43: ...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 44: ...ences 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 wor...

Page 45: ...t 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 reservoi...

Page 46: ...ary 6 22 6 24 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 32 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 tightened Tighten ...

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

Page 48: ... 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 49: ... 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 fo...

Page 50: ...he 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 CAUTIO...

Page 51: ...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 52: ...ING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U2C010E0 book Page 2 Wednesday October 26 2005 10 19 AM ...

Page 53: ...ssary 2 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 Re...

Page 54: ...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 55: ...2 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check o...

Page 56: ...ce 22 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 Front and rear brake switches Check operation 24 Control 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 4000 mi 7000 km or 6 months 8000 mi 13000 km or ...

Page 57: ... 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 25 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the...

Page 58: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U2C010E0 book Page 8 Wednesday October 26 2005 10 19 AM ...

Page 59: ...owling or panel needs to be re moved and installed EAU38970 Cowlings A and B To remove one of the cowlings Remove the bolts and the quick fasten er and then pull the cowling off as shown To install the cowling 1 Fit the tabs on the cowling into the slots and slide it backward 1 Cowling A 2 Cowling C 1 Cowling B 2 Cowling D 3 Cowling E 1 Panel A 2 Panel B 1 Cowling A 2 Bolt 3 Quick fastener U2C010E...

Page 60: ...ing B if remov ing cowling D See page 6 9 2 Disconnect the turn signal light lead coupler 3 Remove the bolts quick fasteners and quick fastener screw and then take the cowling off 1 Cowling A 2 Tab 3 Slot 1 Cowling B 2 Tab 3 Slot 1 Cowling C 2 Bolt 3 Turn signal light lead coupler 4 Quick fastener 1 Quick fastener 1 Quick fastener screw U2C010E0 book Page 10 Wednesday October 26 2005 10 19 AM ...

Page 61: ...ng B to complete the installation of cowling D EAU39091 Cowling E To remove the cowling 1 Remove cowling B and panel B See page 6 9 2 Unfasten the wire harness by pressing on the tab to open the plastic fastener 3 Remove the bolts and the quick fastener and then pull the cowling off as shown 1 Cowling D 2 Bolt 3 Turn signal light lead coupler 4 Quick fastener 1 Quick fastener 1 Quick fastener scre...

Page 62: ...tion and then close the plastic fastener 4 Install the cowling and the panel EAU39060 Panels A and B To remove one of the panels Remove the bolts and then pull the panel off as shown To install the panel Place the panel in the original position and then install the bolts 1 Cowling E 2 Bolt 3 Quick fastener 1 Cowling E 2 Slot 3 Front cowling 4 Tab 1 Panel B 2 Bolt U2C010E0 book Page 12 Wednesday Oc...

Page 63: ... carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads NOTE If a torque wrench is not available when installing a spark plug a good estimate of t...

Page 64: ...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 off 3 Wait a few minutes until the oil set tles 4 Remove the engine oil dipstic...

Page 65: ...he engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 5 11 if the oil filter cartridge is not being replaced 5 Remove the shift arm by removing the bolt 6 Pull the fuel tank breather overflow hoses upward to remove them from the guide 7 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil filler cap 1 Engine oil drain bolt 1 Bolt 2 Shift arm ...

Page 66: ... on the shift arm with the match mark on the shift shaft and installing the bolt then tighten ing it to the specified torque CAUTION ECA15340 Be sure to align the match marks to ensure proper shifting If the match marks are not aligned the shift arm will not move correctly and you may not be able to shift up or down the gears 12 Install the engine oil drain bolt and then tighten it to the specifie...

Page 67: ...a dealer check the vehicle 15 Turn the engine off and then check the oil level and correct it if necessary 16 Install the cowling 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 EAU39083 To check the coolant level 1 Place the vehicle on a level sur face and ho...

Page 68: ...n 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 WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine over...

Page 69: ...e the coolant reservoir cap and then turn the coolant reservoir upside down to empty it 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant reservoir by in stalling the bolts 11 Connect the radiator hose and then move the hose clamp back to its original position 12 Install the coolant drain bolt and then tighten it to the speci...

Page 70: ...wise the effectiveness of the coolant will be reduced 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 17 Start the engine and then check the vehicle for coolant leakag...

Page 71: ...uld 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 valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the per...

Page 72: ...hat can 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 e...

Page 73: ... 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 make ...

Page 74: ...l 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...

Page 75: ...ories 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 3...

Page 76: ...ows 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 lubri...

Page 77: ...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 recommended ...

Page 78: ...ubrication 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 drive...

Page 79: ...oper 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 axle nut to the speci fied torque 4 Tighten the adjusting bolts in direc tion a to their specified torque 5 Tighten the...

Page 80: ... 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 cable...

Page 81: ...should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U2C010E0 book Page 31 Wednesday October 26 2005 10 19 ...

Page 82: ...d lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap ...

Page 83: ...EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly CAUTION ...

Page 84: ...upport the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If ...

Page 85: ...ompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a ...

Page 86: ...s 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Fuel injection system spare fuse 3 Fuel injection system fuse 4 Fuse box 1 5 Backup fuse for odometer and clock 6 ETV electric throttle valve fuse 7 Spare fuse 1 Fuse box 2 2 Right radiator fan fuse 3 Left radiator fan fuse 4 Signaling ...

Page 87: ... 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 care ...

Page 88: ...inner 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 the...

Page 89: ...A11190 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 licens...

Page 90: ...ny 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 wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the r...

Page 91: ...rake 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 EAU34531 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 tha...

Page 92: ...orque 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 ...

Page 93: ... 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 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 b...

Page 94: ...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 self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience...

Page 95: ...ression 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 The...

Page 96: ...ssing 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 the ...

Page 97: ...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 thor...

Page 98: ...ying 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 muffl...

Page 99: ... 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 EAU26180 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 ...

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

Page 101: ... 2 75 US qt 2 29 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 30 L 2 43 US qt 2 02 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 5 L 4 62 US gal 3 85 Imp gal Fuel reserve amount 3 5 L 0 92 US gal 0 77 Imp ...

Page 102: ...93 kg 198 425 lb U49 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 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc ...

Page 103: ...2 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 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 ...

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: ...affixed to the frame under the passenger seat See page 3 15 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer 1 Model label U2C010E0 book Page 2 Wednesday October 26 2005 10 19 AM ...

Page 106: ...gation 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 Transp...

Page 107: ...e 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 Exha...

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 U2C010E0 book Page 6 Wednesday October 26 2005 10 19 AM ...

Page 110: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U2C010E0 book Page 7 Wednesday October 26 2005 10 19 AM ...

Page 111: ...CONSUMER INFORMATION 9 8 9 U2C010E0 book Page 8 Wednesday October 26 2005 10 19 AM ...

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 U2C010E0 book Page 10 Wednesday October 26 2005 10 19 AM ...

Page 114: ...3 16 High beam indicator light 3 2 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 24 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 39 Luggage strap holders 3 22 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance ...

Page 115: ...ights 3 2 Turn signal light bulb replacing 6 39 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 41 Wheel rear 6 43 Wheels 6 24 U2C010E0 book Page 2 Wednesday October 26 2005 10 19 AM ...

Page 116: ...PRINTED IN JAPAN 2005 11 3 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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