OWNER’S MANUAL

FZS600
FZS600SP
5DM-28199-E3
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EAU00001
INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of a FZS600/FZS600SP, you are benefiting from Yamaha’s vast experi-
ence in and newest technology for the design and the manufacture of high-quality
products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your FZS600/
FZS600SP’s advantages. The owner’s manual does not only instruct you in how to
operate, inspect and maintain your motorcycle, but also in how to safeguard yourself
and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in
the best possible condition. If you have any further questions, do not hesitate to con-
tact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put
safety first!
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IMPORTANT MANUAL INFORMATION EAU00005

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

NOTE:
@

● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If there is any
question concerning this manual, please consult your Yamaha dealer.
@
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IMPORTANT MANUAL INFORMATION

EW000002

@
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
@
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IMPORTANT MANUAL INFORMATION

EAU00008

FZS600/FZS600SP
OWNER’S MANUAL
© 1999 by Yamaha Motor Co., Ltd.
1st Edition, September 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
E_5dm_Toc0.fm Page 1 Saturday, October 16, 1999 1:44 PM

EAU00009
TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX
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E_5dm_LabelTOC.fm Page 1 Saturday, October 16, 1999 1:44 PM

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1

1
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GIVE SAFETY THE RIGHT OF WAY

1-
EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving your motorcycle’s value and operating
condition. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders - more than car drivers - must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Though full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively - avoiding all dangers, including those caused by others.

Enjoy your ride!

Give safety the right of way

1-1
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DESCRIPTION

Left view ............................................................................................. 2-1

Right view........................................................................................... 2-2
Controls/Instruments .......................................................................... 2-3

2
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DESCRIPTION
2-
EAU00026

Left view

1. Front fork spring preload adjusting bolt (page 3-16) 7. Luggage strap holder (page 3-17)
2. Starter (choke) “ ” (page 3-14) 8. Seat lock (page 3-14)
3. Air filter (page 6-15) 9. Rear shock absorber spring preload
4. Fuses (page 6-33) adjusting ring (page 3-17)
5. Storage compartment (page 3-15) 10. Shift pedal (page 3-11)
6. Grab bar

2-1
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DESCRIPTION
Right view

11. Luggage strap holder (page 3-17) 16. Front brake fluid master cylinder (page 6-25)
12. Tool kit (page 6-1) 17. Oil level check window (page 6-9)
13. Grab bar 18. Rear brake pedal (page 3-11)
14. Rear brake fluid master cylinder (page 6-26) 19. Coolant reservoir cap (page 6-13)
15. Radiator cap (page 6-14)

2-2
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DESCRIPTION
Controls/Instruments

1. Clutch lever (page 3-10)

2. Left handlebar switches (page 3-9)
3. Speedometer (page 3-6)
4. Main switch (page 3-1)
5. Tachometer (page 3-7)
6. Fuel gauge (page 3-8)
7. Right handlebar switches (page 3-10)
8. Front brake lever (page 3-11)
9. Throttle grip (page 6-19)

2-3
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INSTRUMENT AND CONTROL FUNCTIONS

Main switch/Steering lock .....................................3-1 Rear brake pedal................................................ 3-11

Indicator lights ......................................................3-3 Fuel tank cap ..................................................... 3-12
Oil level indicator circuit check..............................3-4 Fuel .................................................................... 3-13
Fuel indicator circuit check ...................................3-5 Fuel tank breather hose ..................................... 3-13
Speedometer ........................................................3-6 Starter (choke) “ ”........................................... 3-14
Tachometer ...........................................................3-7 Seat.................................................................... 3-14
3
Diagnosis device...................................................3-7 Helmet holder..................................................... 3-15
Antitheft alarm (optional) ......................................3-8 Storage compartment ........................................ 3-15
Fuel gauge............................................................3-8 Front fork adjustment ......................................... 3-16
Handlebar switches ..............................................3-9 Rear shock absorber adjustment ....................... 3-17
Clutch lever .........................................................3-10 Luggage strap holders ....................................... 3-17
Shift pedal...........................................................3-11 Sidestand ........................................................... 3-18
Front brake lever .................................................3-11 Sidestand/clutch switch operation check............ 3-19
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INSTRUMENT AND CONTROL FUNCTIONS

3-
EAU00027

3
1. Push
EAU00029 EAU00040 2. Turn
Main switch/Steering lock LOCK EW000016

The main switch controls the ignition The steering is locked in this position WARNING
@

and lighting systems. Its operation is and all electrical circuits are switched Never turn the key to “OFF” or
described below. off. The key can be removed in this po- “LOCK” when the motorcycle is
EAU00036 sition. To lock the steering, turn the moving. The electrical circuits will
ON handlebars all the way to the left. While be switched off which may result in
Electrical circuits are switched on. The pushing the key into the main switch, loss of control or an accident. Be
engine can be started. The key cannot turn it from “OFF” to “LOCK” and re- sure the motorcycle is stopped be-
be removed in this position. move it. To release the lock, turn the
EAU00038
fore turning the key to “OFF” or
OFF key to “OFF” while pushing. “LOCK”.
@

All electrical circuits are switched off.

The key can be removed in this posi-
tion.

3-1
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INSTRUMENT AND CONTROL FUNCTIONS

EAU03013

(Parking)
The steering is locked in this position,
and the taillights and auxiliary light
come on but all other circuits are off.
The key can be removed in this posi-
tion.
To use the parking position, first lock
3
the steering, then turn the key to “ ”.
Do not use this position for an extend-
ed length of time as the battery may
discharge.

3-2
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00063 EAU01716

High beam indicator light “ ” Coolant temperature indicator light

This indicator comes on when the “ ”
headlight high beam is used. This indicator light comes on when the
engine overheats. If the light comes on,
EAU01313
stop the engine immediately and allow
Oil level indicator light “ ”
the engine to cool.
This indicator comes on when the oil EC000002

3 level is low. This light circuit can be CAUTION:

checked by the procedure on page 3-4. @

1. Left turn indicator light “ ” EC000000

When the engine is overheated, do
2. Neutral indicator light “ ” not continue riding.
3. High beam indicator light “ ” CAUTION: @
@

4. Oil level indicator light “ ” Do not run the motorcycle until you
5. Right turn indicator light “ ” EAU01154
know it has sufficient engine oil.
6. Coolant temperature indicator light “ ”
@
Fuel indicator light “ ”
7. Fuel indicator light “ ”
When the fuel level drops below ap-
EAU00056 NOTE:
Indicator lights
@

proximately 3.5 L, this light will come

Even if the oil is filled to the specified
EAU00058 on. When this light comes on, fill the
level, the indicator light may flicker
Turn indicator lights “ ” “ ” tank at the first opportunity. This light
when riding on a slope or during sud-
The corresponding indicator flashes circuit can be checked by the proce-
den acceleration or deceleration, but
when the turn switch is moved to the dure on page 3-5.
this is normal.
left or right. @

EAU00061

Neutral indicator light “ ”

This indicator comes on when the
transmission is in neutral.

3-3
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00071

Oil level indicator circuit check

CB-48E

Turn the main switch to “ON” and

the engine stop switch to “ ”.

Oil level indicator light Oil level indicator light

does not come on. comes on. 3

Put the transmission in neutral or Check engine oil level.

apply the clutch lever, then push
the start switch.

Oil level indicator light Oil level indicator light Oil level Oil level
comes on. does not come on. is OK. is low.

Engine oil level and Ask a Yamaha dealer to Supply

electrical circuit are OK. inspect electrical circuit. engine oil.
Go ahead with riding.

3-4
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00085

Fuel indicator circuit check

CB-46E

Turn the main switch to “ON” and the

engine stop switch to “ ”.

Fuel indicator light does Fuel indicator light

3 not come on. comes on.

Put the transmission in neutral or Check the fuel level.

apply the clutch lever, then push
the start switch.

Fuel indicator light Fuel indicator light Fuel level Fuel level
comes on. does not come on. is OK. is low.

Fuel level and electrical Ask a Yamaha dealer to Supply fuel.

circuit are OK. inspect electrical circuit.
Go ahead with riding.

3-5
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INSTRUMENT AND CONTROL FUNCTIONS

ride on a tank of fuel. This information To set the clock
will enable you to plan fuel stops in the 1. Push both the “SELECT” and
future. “RESET” buttons for at least two
seconds.
Selecting a mode 2. When the hour digits start flashing,
Push the “SELECT” button to change push the “RESET” button to set
between the odometer mode “ODO” , the hours.
the tripmeter modes “TRIP 1” and 3. Push the “SELECT” button to 3
“TRIP 2”, and the clock mode in the fol- change the minutes.
1. Speedometer
2. Odometer/Tripmeter/Clock lowing order: 4. When the minute digits start flash-
3. “SELECT” button “ODO” → “TRIP 1” → “TRIP 2” → ing, push the “RESET” button to
4. “RESET” button Clock → “ODO” set the minutes.
EAU03028*
5. Push the “SELECT” button to start
Speedometer
Resetting a meter the clock.
This speedometer is equipped with:
To reset either tripmeter 1 or 2 to 0.0,
● an odometer NOTE:
select either by pushing the “SELECT” @

● two tripmeters After setting the clock, be sure to push

button and push the “RESET” button
● a clock the “SELECT” button before turning the
for at least one second.
main switch to “OFF”, otherwise the
Odometer and tripmeter modes clock will not be set.
Clock mode
When set to “ODO”, the motorcycle’s @

To change the display to the clock

total mileage is indicated.
mode, push the “SELECT” button.
When set to “TRIP 1” or “TRIP 2”, the
To change the display back to the
motorcycle’s mileage since the tripme-
odometer mode, push the “SELECT”
ter was last reset is indicated. Use the
button.
tripmeters to estimate how far you can

3-6
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INSTRUMENT AND CONTROL FUNCTIONS

EAU01322*
NOTE:
Diagnosis device @

If the tachometer should display 4,000

This model is equipped with a diagno- instead of 3,000 r/min, the speed sen-
sis device for the Throttle Position Sen- sor may be disconnected or short-cir-
sor (T.P.S.) circuit. cuited. In this case, ask a Yamaha
If some trouble should occur in the cir- dealer to inspect the motorcycle.
cuit, the tachometer will repeatedly dis- @

play as follows:
3 CB-70E

1. Tachometer 0 r/min for 3,000 r/min Current en-

2. Red zone 3 seconds. for 2.5 sec- gine r/min for
onds. 3 seconds.
EAU00101

Tachometer
This model is equipped with an electric If the tachometer displays as described
tachometer so the rider can monitor the above, take your motorcycle to a
engine speed and keep it within the Yamaha dealer for repair.
EC000004
ideal power range.
EC000003 CAUTION:
@

CAUTION: To prevent engine damage, be sure

@

Do not operate in the red zone. to consult a Yamaha dealer as soon

Red zone: 12,500 r/min and above as possible if the tachometer dis-
@
plays a repeated change in r/min.
@

3-7
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00109

Antitheft alarm (optional)

An antitheft alarm can be equipped to
this motorcycle. Consult your Yamaha
dealer to obtain and install the alarm.

3
1. Fuel gauge
EAU00110

Fuel gauge
This model is equipped with an electric
fuel gauge so the rider can monitor the
fuel level in the fuel tank. When the
needle indicates “E” (Empty), about
3.5 L remain in the fuel tank.

3-8
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00127
NOTE:
Turn signal switch @

Turn on the hazard switch to warn oth-

To signal a right-hand turn, push the
er drivers if your motorcycle must be
switch to “ ”. To signal a left-hand
stopped where it might be a traffic haz-
turn, push the switch to “ ”. Once the
ard.
switch is released it will return to the @

center position. To cancel the signal,

push the switch in after it has returned
3
to the center position.
1. Pass switch “PASS”
2. Dimmer switch EAU00129

3. Turn signal switch Horn switch “ ”

4. Horn switch “ ” Press the switch to sound the horn.
5. Hazard switch “ ”
EAU00118

Handlebar switches Hazard switch “ ”

EAU00144

EAU00120

Pass switch “PASS” The hazard switch should be turned on

Press the switch to operate the passing under emergency or hazardous condi-
light. tions. All turn signal lights will flash si-
multaneously when this switch is
EAU00121 turned on with the main switch in the
Dimmer switch “ON” or “P” position.
Turn the switch to “ ” for the high EC000006

beam and to “ ” for the low beam. CAUTION:

@

The battery can discharge from ex-

tended use, making it difficult to op-
erate the starter.
@

3-9
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00134

Lights switch
Turning the light switch to “ ”,
turns on the auxiliary light, meter lights
and taillight. Turning the light switch to
“ ” turns the headlight on also.

EAU00143

Start switch “ ” 3
The starter motor cranks the engine
1. Engine stop switch 1. Clutch lever
2. Lights switch when pushing the start switch. EAU00152

3. Start switch “ ” EC000005

Clutch lever
EAU00138 CAUTION: The clutch lever is located on the left
Engine stop switch @

See starting instructions prior to handlebar, and the ignition circuit cut-
The engine stop switch is a safety de-
starting the engine. off system is incorporated in the clutch
vice for use in an emergency such as @

lever holder. Pull the clutch lever to the

when the motorcycle overturns or if
handlebar to disengage the clutch, and
trouble occurs in the throttle system.
release the lever to engage the clutch.
Turn the switch to “ ” to start the en-
The lever should be pulled rapidly and
gine. In case of emergency, turn the
released slowly for smooth clutch oper-
switch to “ ” to stop the engine.
ation. (Refer to the engine starting pro-
cedures for a description of the ignition
circuit cut-off system.)

3-10
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Shift pedal 1. Front brake lever 1. Rear brake pedal
EAU00157 2. Lever position adjuster EAU00162

Shift pedal 3. Arrow mark Rear brake pedal

a. Lever distance
This motorcycle is equipped with a con- EAU00161
The rear brake pedal is on the right
stant-mesh 6-speed transmission. Front brake lever side of the motorcycle. Press down on
The shift pedal is located on the left The front brake lever is located on the the brake pedal to apply the rear brake.
side of the engine and is used in com- right handlebar and is equipped with a
bination with the clutch when shifting. brake lever adjusting dial. To activate
the front brake, pull the lever toward
the handlebar. To adjust the front brake
lever position, turn the brake lever ad-
justing dial while pulling the lever for-
ward. Make sure the setting on the
brake lever adjusting dial is aligned
with the arrow mark.

3-11
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INSTRUMENT AND CONTROL FUNCTIONS

NOTE:
@

This tank cap cannot be closed unless

the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
@

EW000023

@
WARNING
Be sure the cap is properly installed 3
1. Lock cover and locked in place before riding the
2. Open motorcycle.
EAU02935 @

Fuel tank cap

To open
Open the lock cover. Insert the key and
turn it 1/4 turn clockwise. The lock will
be released and the cap can be
opened.

To close
Push the tank cap into position with the
key inserted. To remove the key, turn it
counterclockwise to the original posi-
tion. Then, close the lock cover.

3-12
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00185

CAUTION:
@

Always wipe off spilled fuel immedi-

ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.
@

EAU00191

3
Recommended fuel:
1. Filler tube 1. Fuel tank breather hose
2. Fuel level
Regular unleaded gasoline with a EAU02955
EAU01183 research octane number of 91 or Fuel tank breather hose
Fuel higher. This model is equipped with a fuel tank
Make sure there is sufficient fuel in the Fuel tank capacity: breather hose.
tank. Fill the fuel tank to the bottom of Total: Before using this motorcycle:
the filler tube as shown in the illustra- 20 L ● Check the fuel tank breather hose
tion. Reserve: connection.
EW000130
3.5 L ● Check the fuel tank breather hose
@
WARNING for cracks or damage and replace
Do not overfill the fuel tank. Avoid NOTE:
@
it if damaged.
spilling fuel on the hot engine. Do If knocking or pinging occurs, use a dif-
● Make sure the end of the fuel tank
not fill the fuel tank above the bot- ferent brand of gasoline or higher oc-
breather hose is not blocked and
tom of the filler tube or it may over- tane grade.
@
clean it if necessary.
flow when the fuel heats up later and
expands.
@

3-13
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Starter (choke) “ ” 1. Seat lock 1. Projection
EAU02976 2. Open 2. Seat holder
Starter (choke) “ ” EAU01319
To install
Starting a cold engine requires a richer Seat Insert the projection on the rear of the
air-fuel mixture. A separate starter cir- To remove seat into the seat holder, then push
cuit supplies this mixture. Insert the key into the seat lock and down on the front of the seat.
Move in direction a to turn on the turn it counterclockwise. While holding
starter (choke). the key in that position, lift up the front
Move in direction b to turn off the of the seat.
starter (choke).

3-14
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Helmet holder 1. Storage compartment 1. U-LOCK
EAU00263 EAU01688 2. Strap
Helmet holder Storage compartment
The helmet holder is under the seat. This compartment is designed to store
Remove the seat and hook the helmet a genuine Yamaha U-LOCK. (Other
on the helmet holder. Then, reinstall locks may not fit.)
the seat and lock it. Be sure the lock is fastened securely
EW000030
with the straps when storing it in the
@
WARNING compartment.
Never ride with a helmet in the hel- To prevent losing the straps, be sure to
met holder. The helmet may hit ob- secure them even when a U-LOCK is
jects, causing loss of control and not being stored in the compartment.
possibly an accident. When storing this Owner’s manual or
@

other documents in the compartment,

be sure to put them in a vinyl bag so
they do not get wet. When washing the
motorcycle, be careful not to flood this
compartment with water.

3-15
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Spring preload adjusting bolt 1. Setting position
EAU00285 2. Front fork cap
Front fork adjustment EC000013

This front fork is equipped with spring CAUTION:

@

preload adjusting bolts. The grooves are provided to show

EW000037
the adjustment level. Always keep
@
WARNING the adjustment level equal on both
Each fork leg must be set to the fork legs.
same pressure. Uneven setting can @

CI-18E
cause poor handling and loss of sta- Hard
Stan-
Soft
dard
bility.
@ Adjusting
1 2 3 4 5 6 7
Adjust spring preload as follows. Turn position

the adjusting bolts in direction a to in-

crease spring preload and in
direction b to decrease spring pre-
load.

3-16
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00315

@
WARNING
This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following infor-
mation before handling the shock
absorber. The manufacturer cannot
3 be held responsible for property
damage or personal injury that may
1. Spring preload adjusting ring 1. Luggage strap holder (× 2)
2. Special wrench
result from improper handling. EAU01311
EAU00295 ● Do not tamper with or attempt to Luggage strap holders
Rear shock absorber open the cylinder assembly. There are two luggage strap holders
adjustment ● Do not subject the shock ab- below the rear of the seat which can be
This shock absorber is equipped with a sorber to an open flame or other turned outward for easier access.
spring preload adjusting ring. Adjust high heat source. This may
spring preload as follows. Turn the ad- cause the unit to explode due to
justing ring in direction a to increase excessive gas pressure.
spring preload and in direction b to de- ● Do not deform or damage the
crease spring preload. Make sure that cylinder in any way. Cylinder
the appropriate notch in the adjusting damage will result in poor
ring is aligned with the position indica- damping performance.
tor on the rear shock absorber. ● Take your shock absorber to a
CI-18E Yamaha dealer for any service.
Stan- @

Hard Soft
dard
Adjusting
9 8 7 6 5 4 3 2 1
position

3-17
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00330 EW000044

Sidestand WARNING
@

This model is equipped with an ignition This motorcycle must not be operat-
circuit cut-off system. The motorcycle ed with the sidestand in the down
must not be ridden when the sidestand position. If the stand is not properly
is down. The sidestand is located on retracted, it could contact the
the left side of the frame. (Refer to ground and distract the operator, re-
page 5-1 for an explanation of this sys- sulting in a possible loss of control. 3
tem.) Yamaha has designed into this
motorcycle a lockout system to as-
sist the operator in fulfilling the re-
sponsibility of retracting the
sidestand. Please check carefully
the operating instructions listed be-
low and if there is any indication of a
malfunction, return the motorcycle
to a Yamaha dealer immediately for
repair.
@

3-18
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00332 CD-08E

Sidestand/clutch switch CLUTCH SWITCH IS OK.

operation check
Check the operation of the sidestand
SIDESTAND IS DOWN.
switch and clutch switch against the in-
formation below.
EW000046
ENGINE WILL STALL.
WARNING
3 @

● Be sure to use the centerstand

during this inspection. SIDESTAND SWITCH IS OK.
● If improper operation is noted,
consult a Yamaha dealer.
@

CD-08E

TURN MAIN SWITCH TO “ON” AND

ENGINE STOP SWITCH TO “ ”.

TRANSMISSION IS IN GEAR AND

SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH START SWITCH.

ENGINE WILL START.

3-19
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PRE-OPERATION CHECKS

Pre-operation check list...................................................................... 4-1

4
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PRE-OPERATION CHECKS
4-
EAU01114

Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340

PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE
Front brake • Check operation, free play, fluid level and fluid leakage.
6-24 ~ 6-26
Rear brake • Fill with DOT 4 brake fluid if necessary.
4 • Check operation condition and free play.
Clutch 6-23
• Adjust if necessary.
• Check for smooth operation.
Throttle grip and housing 6-19, 6-28
• Lubricate if necessary.
• Check oil level.
Engine oil 6-9 ~ 6-11
• Fill with oil if necessary.
• Check coolant level.
Coolant reservoir tank 6-12 ~ 6-15
• Fill with coolant if necessary.
• Check chain slack and condition.
Drive chain 6-27 ~ 6-28
• Adjust if necessary.
6-19 ~ 6-22
Wheels and tires • Check tire pressure, wear and damage.
6-35 ~ 6-38
• Check for smooth operation.
Control cables 6-28
• Lubricate if necessary.
Brake and shift pedal • Check for smooth operation.
6-29
shafts • Lubricate if necessary.
Brake and clutch lever • Check for smooth operation.
6-29
pivots • Lubricate if necessary.

4-1
E_5dm_Preop.fm Page 2 Saturday, October 16, 1999 1:46 PM

PRE-OPERATION CHECKS
ITEM CHECKS PAGE
Center and sidestand • Check for smooth operation.
6-29
pivots • Lubricate if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
• Check fuel level.
Fuel 3-12 ~ 3-13
• Fill with fuel if necessary.
Lights, signals and
• Check for proper operation. 6-33 ~ 6-35
switches

4
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.

WARNING
If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating
the motorcycle.

4-2
E_5dm_Preop.fm Page 3 Saturday, October 16, 1999 1:46 PM
E_5dm_OperationTOC.fm Page 1 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine............................................................................. 5-1

Starting a warm engine ...................................................................... 5-4
Shifting ............................................................................................... 5-4
Recommended shift points (for Switzerland only) .............................. 5-5
Tips for reducing fuel consumption .................................................... 5-5
Engine break-in .................................................................................. 5-5
Parking ............................................................................................... 5-6

5
 E_5dm_Operation.fm Page 1 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

5-
EAU00372

EAU00373 EAU01627*

WARNING Starting the engine

@

● Before riding this motorcycle,

NOTE:
become thoroughly familiar
@

This motorcycle is equipped with an ig-

with all operating controls and nition circuit cut-off system.
their functions. Consult a The engine can be started only under
Yamaha dealer regarding any one of the following conditions:
control or function that you do ● The transmission is in neutral.
not thoroughly understand. ● The sidestand is up, the transmis-
● Never start your engine or let it sion is in gear and the clutch is dis-
run for any length of time in a engaged.
closed area. The exhaust fumes The motorcycle must not be ridden
5
are poisonous and can cause when the sidestand is down.
loss of consciousness and @

EW000054
death within a short time. Al-
WARNING
ways operate your motorcycle @

in an area with adequate ventila- Before going through the following

tion. steps, check the function of the
sidestand switch and clutch switch.
● Before starting out, always be
(Refer to page 3-19.)
sure the sidestand is up. Failure @

to retract the sidestand com-

pletely can result in a serious
accident when you try to turn a
corner.
@

5-1
E_5dm_Operation.fm Page 2 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

CF-28E

TURN THE MAIN SWITCH TO “ON” AND THE

ENGINE STOP SWITCH TO “ ”.

IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND

SIDESTAND IS DOWN, SIDESTAND IS UP,

PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH THE
ENGINE WILL START. START SWITCH. ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT 5

TRANSMISSION IN GEAR.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

5-2
 E_5dm_Operation.fm Page 3 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

1. Turn the main switch to “ON” and NOTE:
@
5. After starting the engine, move the
the engine stop switch to “ ”. If the engine fails to start, release the starter (choke) to the halfway posi-
EC000035 start switch, wait a few seconds, then tion.
CAUTION: try again. Each attempt should be as
NOTE:
@

If the fuel indicator light comes on, short as possible to preserve the bat- @

tery. Do not crank the engine more For maximum engine life, never accel-
check the fuel level. If necessary, fill
erate hard with a cold engine!
the tank with fuel. than 10 seconds on any one attempt. @

6. After the engine is warm, turn off

@
@

EC000036
2. Shift the transmission into neutral.
CAUTION: the starter (choke) completely.
@

NOTE: The oil level indicator light and fuel NOTE:

@

When the transmission is in neutral, the indicator light should come on when
@

The engine is warm when it responds

neutral indicator light should be on. If the start switch is pushed and
5 normally to the throttle with the starter
the light does not come on, ask a should go off when the start switch (choke) turned off.
Yamaha dealer to inspect it. is released. If the oil level indicator @

3. Turn on the starter (choke) and light flickers or remains on, immedi-
completely close the throttle grip. ately stop the engine and check the
4. Start the engine by pushing the engine oil level and for oil leakage. If
start switch. necessary, fill the engine with oil
and check to see that the oil level in-
dicator light goes off. If not, consult
a Yamaha dealer.
@

5-3
E_5dm_Operation.fm Page 4 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU01258 EC000048

Starting a warm engine CAUTION:

@

The starter (choke) is not required ● Do not coast for long periods
when the engine is warm. with the engine off, and do not
EC000046
tow the motorcycle a long dis-
CAUTION:
@ tance. Even with gears in neu-
See the “Engine break-in” section tral, the transmission is only
prior to operating the motorcycle for properly lubricated when the
the first time. engine is running. Inadequate
@
1. Shift pedal
N. Neutral
lubrication may damage the
EAU00423 transmission.
Shifting ● Always use the clutch when
5
The transmission lets you control the changing gears. The engine,
amount of power you have available at transmission, and driveline are
a given speed for starting, accelerating, not designed to withstand the
climbing hills, etc. The use of the shift shock of forced shifting and can
pedal is shown in the illustration. be damaged by shifting without
To shift into neutral, depress the shift using the clutch.
pedal repeatedly until it reaches the @

end of its travel, then raise the pedal

slightly.

5-4
 E_5dm_Operation.fm Page 5 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU02937 EAU00424 EAU01128

Recommended shift points Tips for reducing fuel Engine break-in

(for Switzerland only) consumption There is never a more important period
The recommended shift points are Your motorcycle’s fuel consumption in the life of your motorcycle than the
shown in the table below. depends to a large extent on your period between zero and 1,600 km. For
CF-26E
riding style. The following tips can help this reason we ask that you carefully
Acceleration shift point
(km/h) reduce fuel consumption: read the following material. Because
1st → 2nd 20 ● Warm up the engine before riding. the engine is brand new, you must not
2nd → 3rd 30 ● Turn off the starter (choke) as put an excessive load on it for the first
3rd → 4th 40 soon as possible. 1,600 km. The various parts in the en-
4th → 5th 50
● Shift up swiftly and avoid high en- gine wear and polish themselves to the
5th → 6th 60
gine speeds during acceleration. correct operating clearances. During
5 NOTE: ● Do not double-clutch or rev the en- this period, prolonged full throttle oper-
@

When shifting two gears down from 5th gine while shifting down and avoid ation, or any condition which might re-
to 3rd, bring your motorcycle to a high engine speeds with no load sult in excessive heating of the engine,
speed of 35 km/h. on the engine. must be avoided.
@

● Turn off the engine instead of let-

ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.

5-5
E_5dm_Operation.fm Page 6 Saturday, October 16, 1999 1:46 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU01329 EAU00460

0 ~ 1,000 km Parking
Avoid operation above 5,000 r/min. When parking the motorcycle, stop the
engine and remove the ignition key.
1,000 ~ 1,600 km EW000058

Avoid cruising speeds in excess of @

WARNING
6,000 r/min. The exhaust system is hot. Park the
EC000052
motorcycle in a place where pedes-
CAUTION: trians or children are not likely to
@

After 1,000 km of operation, be sure touch the motorcycle. Do not park

to replace the engine oil and oil fil- the motorcycle on a slope or soft
ter. ground; the motorcycle may over-
@

turn. 5
@

1,600 km and beyond

Proceed with normal riding.
EC000053

CAUTION:
@

● Never let engine speeds enter

the red zone.
● If any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
@

5-6
E_5dm_Operation.fm Page 7 Saturday, October 16, 1999 1:46 PM
E_5dm_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 1:46 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit...................................................................6-1 Drive chain slack adjustment ............................. 6-27

Periodic maintenance and lubrication...................6-2 Drive chain lubrication........................................ 6-28
Panel removal and installation ..............................6-5 Cable inspection and lubrication ........................ 6-28
Panel A, C.............................................................6-5 Throttle cable and grip lubrication ...................... 6-28
Panel B .................................................................6-6 Brake and shift pedal lubrication ........................ 6-29
Spark plugs...........................................................6-7 Brake and clutch lever lubrication ...................... 6-29
Engine oil ..............................................................6-9 Center and sidestand lubrication ....................... 6-29
Cooling system ...................................................6-12 Rear suspension lubrication............................... 6-30
Changing the coolant..........................................6-13 Front fork inspection........................................... 6-30
Air filter ...............................................................6-15 Steering inspection ............................................ 6-31
Carburetor adjustment ........................................6-18 Wheel bearings .................................................. 6-31
Idle speed adjustment ........................................6-18 Battery................................................................ 6-31
6
Throttle cable free play inspection ......................6-19 Fuse replacement .............................................. 6-33
Valve clearance adjustment ................................6-19 Headlight bulb replacement ............................... 6-33
Tires....................................................................6-19 Taillight bulb replacement................................... 6-35
Wheels................................................................6-22 Turn signal light bulb replacement...................... 6-35
Clutch lever free play adjustment........................6-23 Front wheel removal........................................... 6-35
Rear brake pedal height check ...........................6-23 Front wheel installation ...................................... 6-36
Brake light switch adjustment .............................6-24 Rear wheel removal ........................................... 6-37
Checking the front and rear brake pads..............6-25 Rear wheel installation ....................................... 6-38
Inspecting the brake fluid level............................6-25 Troubleshooting.................................................. 6-39
Brake fluid replacement ......................................6-26 Troubleshooting chart......................................... 6-40
Drive chain slack check ......................................6-27
 E_5dm_Periodic.fm Page 1 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-
EAU00462

EAU00464
NOTE:
Periodic inspection, adjustment and lu- @

If you do not have necessary tools re-

brication will keep your motorcycle in
quired during a service operation, take
the safest and most efficient condition
your motorcycle to a Yamaha dealer for
possible. Safety is an obligation of the
service.
motorcycle owner. The maintenance @

EW000063
and lubrication schedule chart should
be considered strictly as a guide to @
WARNING
general maintenance and lubrication Modifications to this motorcycle not
intervals. YOU MUST TAKE INTO 1. Tool kit approved by Yamaha may cause
CONSIDERATION THAT WEATHER, EAU01299 loss of performance, and render it
TERRAIN, GEOGRAPHICAL LOCA-
Tool kit unsafe for use. Consult a Yamaha
TIONS, AND A VARIETY OF INDIVID- The tool kit is located inside the storage dealer before attempting any chang-
UAL USES ALL TEND TO DEMAND compartment under the seat. (See es.
page 3-14 for seat opening proce- @

6 THAT EACH OWNER ALTER THIS

TIME SCHEDULE TO SHORTER IN- dures.) The tools provided in the own-
TERVALS TO MATCH THE ENVI- er’s tool kit are to assist you in the
performance of periodic maintenance.
RONMENT. The most important points
of motorcycle inspection, adjustment, However, some other tools such as a
and lubrication are explained in the fol- torque wrench are also necessary to
perform the maintenance correctly.
lowing pages.
EW000060 The service information included in this
WARNING manual is intended to provide you, the
owner, with the necessary information
@

If you are not familiar with motor-

cycle service, this work should be for completing some of your own pre-
done by a Yamaha dealer. ventive maintenance and minor re-
@ pairs.

6-1
E_5dm_Periodic.fm Page 2 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00473

PERIODIC MAINTENANCE AND LUBRICATION

CP-01E
EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check fuel hoses for cracks or damage.
1 * Fuel line √ √
• Replace if necessary.
• Check condition.
2 * Fuel filter √
• Replace if necessary.
• Check condition.
3 Spark plugs √ √ √
• Clean, regap or replace if necessary.
• Check valve clearance. Every 42,000 km or 42 months
4 * Valves • Adjust if necessary. (whichever comes first)
5 Air filter • Clean or replace if necessary. √ √
6
• Check operation.
6 Clutch √ √ √
• Adjust or replace cable.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
7 * Front brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
8 * Rear brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check balance, runout and for damage.
9 * Wheels √ √
• Rebalance or replace if necessary.
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √
• Check air pressure.
• Correct if necessary.

6-2
 E_5dm_Periodic.fm Page 3 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check bearing for looseness or damage.
11 * Wheel bearings √ √
• Replace if necessary.
• Check swingarm pivoting point for play.
• Correct if necessary.
12 * Swingarm √ √
• Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly Every 1,000 km and after washing the
13 Drive chain
aligned. motorcycle or riding in the rain
• Clean and lubricate.
• Check bearing play and steering for roughness.
• Correct accordingly.
14 * Steering bearings √ √
6 • Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
• Make sure that all nuts, bolts and screws are properly tightened.
15 * Chassis fasteners √ √
• Tighten if necessary.
• Check operation.
16 Sidestand/centerstand √ √
• Lubricate and repair if necessary.
• Check operation.
17 * Sidestand switch √ √ √
• Replace if necessary.
• Check operation and for oil leakage.
18 * Front fork √ √
• Correct accordingly.
Rear shock absorber • Check operation and shock absorber for oil leakage.
19 * assembly √ √
• Replace shock absorber assembly if necessary.
Rear suspension relay • Check operation.
20 * arm and connecting arm • Lubricate with molybdenum disulfide grease every 24,000 km or √ √
pivoting points 24 months (whichever comes first).

6-3
E_5dm_Periodic.fm Page 4 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check engine idling speed, synchronization and starter operation.
21 * Carburetors √ √ √
• Adjust if necessary.
• Check oil level and vehicle for oil leakage.
22 Engine oil • Correct if necessary. √ √ √
• Change. (Warm engine before draining.)
23 Engine oil filter cartridge • Replace. √ √
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
24 * Cooling system √ √
• Change coolant every 24,000 km or 24 months (whichever comes
first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
6
NOTE:
@

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regu-
larly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@

6-4
 E_5dm_Periodic.fm Page 5 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel A 1. Panel C 1. Panel A

2. Panel B 2. Bolt
EAU01122 EAU00491

Panel removal and installation Panel A, C

The panels illustrated need to be re- To remove
moved to perform some of the mainte- Remove the bolt and pull outward on
6 nance described in this chapter. Refer the areas shown.
to this section each time a panel has to
be removed or reinstalled. To install
Place the panel in its original position
and install the bolt.

6-5
E_5dm_Periodic.fm Page 6 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel C 1. Panel B
2. Bolt 2. Screw (× 3)
EAU01315

Panel B
To remove
Remove the screws.
6
To install
Place the panel in the original position
and install the screws.

6-6
 E_5dm_Periodic.fm Page 7 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

ly remove and inspect the spark plugs
because heat and deposits will cause
any spark plug to slowly break down
and erode. If electrode erosion be-
comes excessive, or if carbon and oth-
er deposits are excessive, you should
replace the spark plug with the speci-
fied plug.
1. Spark plug cap 1. Spark plug wrench
Specified spark plug:
EAU01485*
Inspection
Spark plugs The spark plug is an important engine
Except for D, F
Removal CR8E, CR9E (NGK) or
component and is easy to inspect. The
1. Remove the spark plug caps. U24ESR-N, U27ESR-N
condition of the spark plug can indicate
2. Use the spark plug wrench in the (DENSO)
6 the condition of the engine. Normally,
tool kit to remove the spark plugs For D, F
all spark plugs from the same engine
as shown. CR7E, CR8E, CR9E (NGK) or
should have the same color on the
U22ESR-N, U24ESR-N,
white insulator around the center elec-
U27ESR-N (DENSO)
trode. The ideal color at this point is a
medium-to-light tan color for a motor-
cycle that is being ridden normally. If
one spark plug shows a distinctly differ-
ent color, there could be something
wrong with the engine. Do not attempt
to diagnose such problems yourself. In-
stead, take the motorcycle to a
Yamaha dealer. You should periodical-
6-7
E_5dm_Periodic.fm Page 8 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Install the spark plug and tighten it
to the specified torque.

Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kg)

NOTE:
@

If a torque wrench is not available when

a. Spark plug gap you are installing a spark plug, a good
Installation estimate of the correct torque is 1/4 to
1. Measure the electrode gap with a 1/2 turn past finger tight. Have the
wire thickness gauge and, if nec- spark plug tightened to the specified
essary, adjust the gap to specifica- torque as soon as possible.
tion. @

Spark plug gap:

0.7 ~ 0.8 mm

2. Clean the gasket surface. Wipe off

any grime from the threads.

6-8
 E_5dm_Periodic.fm Page 9 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.

NOTE:
@

Wait a few minutes until the oil level

settles before checking.
@

3. The oil level should be between

1. Oil level check window 1. Engine oil filler cap
2. Maximum level mark
the maximum and minimum
Engine oil and oil filter cartridge re-
3. Minimum level mark marks. If the level is low, fill the en-
placement
EAU01717 gine with sufficient oil to reach the
Engine oil 1. Warm up the engine for several
specified level.
Oil level inspection minutes.
6 1. Place the motorcycle on the cen- 2. Stop the engine. Place an oil pan
terstand. Warm up the engine for under the engine and remove the
several minutes. oil filler cap.

NOTE:
@

Be sure the motorcycle is positioned

straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.
@

6-9
E_5dm_Periodic.fm Page 10 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil drain bolt 1. Oil filter wrench 1. O-ring

3. Remove the drain bolt and drain 2. Oil filter cartridge 6. Apply a light coat of engine oil to
the oil. 4. Remove the oil filter by using an oil the O-ring of the new oil filter.
filter wrench.
NOTE:
@
NOTE:
@

When draining the engine oil, use a NOTE:

@ Make sure the O-ring is seated proper-
funnel or similar device to keep oil An oil filter wrench is available at a ly. 6
away from the exhaust pipe. nearby Yamaha dealer. @

@
@

5. Reinstall the drain bolt and tighten

it to the specified torque.

Tightening torque:
Drain bolt:
43 Nm (4.3 m·kg)

6-10
 E_5dm_Periodic.fm Page 11 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

9. Start the engine and warm it up for
Recommended oil:
several minutes. While warming
See page 8-1.
up, check for oil leakage. If oil
Oil quantity:
leakage is found, stop the engine
Total amount:
immediately and check for the
3.5 L
cause.
Periodic oil change:
2.5 L NOTE:
@

With oil filter replacement: After the engine is started, the oil level
1. Torque wrench 2.7 L indicator light should go off if the oil is at
7. Install the new oil filter and tighten the specified level.
EC000066
it to the specified torque with an oil @

EC000067
CAUTION:
filter wrench. @
CAUTION:
● Do not put in any chemical addi- @

NOTE: tives. Engine oil also lubricates If the indicator light flickers or re-
6
@

When installing the oil filter, tighten it to the clutch and additives could mains on, immediately stop the en-
the proper torque by using a torque cause clutch slippage. gine and consult with a Yamaha
wrench. ● Be sure no foreign material en-
dealer.
@
@

ters the crankcase.

Tightening torque:
@

Oil filter:
17 Nm (1.7 m·kg)

8. Fill the engine with sufficient oil to

reach the specified level. Install
the oil filler cap and tighten it.

6-11
E_5dm_Periodic.fm Page 12 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Reservoir tank capacity:
0.61 L
EC000080

CAUTION:
@

Hard water or salt water is harmful

to the engine. You may use distilled
water if you can’t get soft water.
@

1. Reservoir tank
2. Maximum level mark NOTE:
@

3. Minimum level mark ● If water is added, have a Yamaha

EAU01718
dealer check the antifreeze con-
Cooling system tent of the coolant as soon as pos-
1. Remove panel A. (See page 6-5 sible.
for panel removal and installation ● The radiator fan operation is com-
6
procedures.) pletely automatic. It is switched on
2. Check the coolant level in the res- or off according to the coolant tem-
ervoir tank when the engine is cold perature in the radiator.
as the coolant level will vary with @

engine temperature. The coolant If your motorcycle overheats, see page

level should be between the maxi- 6-41 for details.
mum and minimum marks.
3. If the level is low, add coolant or
distilled water to raise it to the
specified level.
4. Install the panel.

6-12
 E_5dm_Periodic.fm Page 13 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt (× 2) 1. Hose 1. Coolant drain bolt

EAU01719* 2. Fuel cock 2. Sidestand switch lead
Changing the coolant 3. Fuel level sensor connector 3. Plastic holder
1. Place the motorcycle on the cen- 4. Lift the fuel tank upward and turn 7. Remove the sidestand switch lead
terstand. the fuel cock to “OFF”. from its holder.
2. Remove the seat. 5. Disconnect the fuel level sensor 8. Place a container under the en-
6 connector. gine and remove the coolant drain
3. Remove the fuel tank bolts.
6. Pull the hose off the fuel cock, bolt to drain the coolant from the
then remove the tank. water pump.
9. Hold the container close to the
drain hole and remove the radiator
cap to drain the remaining coolant.

NOTE:
@

When draining the coolant, use a fun-

nel or similar object to keep coolant
away from the frame.
@

6-13
E_5dm_Periodic.fm Page 14 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Radiator cap 1. Plastic holder

2. Overflow hose 12. Remove the hose holder from the 13. Pull the hose all the way down and
EW000067
frame. to the outside while making sure to
@
WARNING keep the end up. Then, tilt the
Do not remove the radiator cap hose downward into the container
when the engine is hot. to drain the coolant from the reser-
@
6
10. Remove the coolant reservoir tank voir tank.
cap.
NOTE:
11. Remove the radiator overflow @

Take careful note of the radiator over-

hose from the top of the radiator.
flow hose’s original routing to ensure
proper installation.
@

14. After draining the coolant, thor-

oughly flush the cooling system
with clean tap water.

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PERIODIC MAINTENANCE AND MINOR REPAIR

15. Replace the coolant drain bolt EC000080 EAU03016

washer if it is damaged and tighten CAUTION: Air filter

@

the coolant drain bolt to the speci- Hard water or salt water is harmful The air filter element should be cleaned
fied torque. to the engine. You may use distilled at the specified intervals. It should be
water if you can’t get soft water. cleaned more frequently if you are
Tightening torque:
@
riding in unusually wet or dusty areas.
18. Install the hose to the fuel cock, 1. Remove the seat. (See page 3-14
Coolant drain bolt:
turn the fuel cock to “ON” and tem- for seat removal and installation
10 Nm (1.0 m·kg)
porarily place back the fuel tank. procedures.)
16. Install the radiator overflow hose. 19. Run the engine several minutes. 2. Remove the fuel tank. (Refer to
Make sure it is properly routed. Stop the engine, lift the fuel tank “Changing the coolant” for details
17. Pour the recommended coolant slightly upward and recheck the on how to remove the fuel tank.)
into the radiator until it is full. coolant level in the radiator. If it is EW000071

low, add more coolant until it WARNING

@

6 Recommended antifreeze: reaches the top of the radiator. ● Support the fuel tank carefully
High quality ethylene glycol anti- 20. Fill the reservoir tank with coolant during this procedure.
freeze containing corrosion inhib- up to the maximum level. ● Do not tilt the fuel tank too
itors for aluminum engines. 21. Install the radiator cap and reser- much or pull it too hard because
Antifreeze and water mixing ratio: voir tank cap. Check for coolant the fuel hose connections may
1:1 leakage. become loose causing fuel
Total amount: leakage.
NOTE:
@ @

1.95 L If any leakage is found, ask a Yamaha 3. Remove panels A, B and C. (See
Reservoir tank capacity: dealer to inspect the cooling system. pages 6-5 and 6-6 for panel re-
0.61 L @

moval and installation proce-

22. Install the fuel tank bolts.
dures.)

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Rubber cover 1. Air filter case cover

2. Holder 2. Screw (× 4)
4. Remove the rubber cover from its 5. Remove the screws holding the air
holders by pushing it downward. filter case cover.
Then pull it upward and back as
shown, away from the air filter
6
case.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000072

@
WARNING
● Before reinstallation, make sure
that the fuel hoses are not dam-
aged at all. If any damage is
found, it may result in a fuel
leak, so do not start the engine.
Ask a Yamaha dealer for re-
pairs.
1. Air filter element
● Always make sure that the fuel
6. Pull out the air filter element. 7. Tap the air filter element lightly to
hoses are properly connected,
remove most of the dust and dirt.
in place, and not pinched.
Blow out the remaining dirt with @

compressed air from the mesh

6 side of the air filter element. If it is
damaged, replace it.
8. Install by reversing the removal
procedure.
EC000085

CAUTION:
@

● Make sure the air filter is prop-

erly seated in the filter case.
● The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00630

Carburetor adjustment Standard idle speed:

The carburetors are important parts of 1,150 ~ 1,250 r/min
the engine and require very sophisti-
cated adjustment. Most adjustments NOTE:
@

should be left to a Yamaha dealer who If the specified idle speed cannot be
obtained by performing the above ad-
has the professional knowledge and
experience to do so. However, the idle justment, consult a Yamaha dealer.
@

speed may be adjusted by the owner

as part of routine maintenance. 1. Throttle stop screw
EAU00632
EC000095

CAUTION:
Idle speed adjustment
@
1. Start the engine and warm it up
The carburetors were set at the
for a few minutes at approximate-
Yamaha factory after many tests. If
ly 1,000 to 2,000 r/min. Occasion-
they are changed, poor engine per- 6
ally rev the engine to 4,000 to
formance and damage may result.
@
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection a to increase engine
speed and in direction b to de-
crease engine speed.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00637 EAU00658

Valve clearance adjustment Tires

The correct valve clearance changes To ensure maximum performance,
with use, resulting in improper fuel/air long service and safe operation, note
supply or engine noise. To prevent this, the following:
the valve clearance must be adjusted
regularly. This adjustment however, Tire air pressure
should be left to a professional Always check and adjust the tire pres-
Yamaha service technician. sure before operating the motorcycle.
a. Free play EW000082

EAU00635
WARNING
Throttle cable free play @

Tire inflation pressure should be

inspection checked and adjusted when the
There should be a free play of 3 ~ temperature of the tire equals the
6 5 mm at the throttle grip. If the free play ambient air temperature. Tire infla-
is incorrect, ask a Yamaha dealer to tion pressure must be adjusted ac-
make this adjustment. cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

CE-33E EW000083
Maximum load* 187 kg
Cold tire pressure Front Rear @
WARNING
225 kPa 250 kPa Proper loading of your motorcycle
Up to 90 kg load* (2.25 kg/cm2, (2.50 kg/cm2,
is important for several characteris-
2.25 bar) 2.50 bar)
225 kPa 290 kPa
tics of your motorcycle, such as
90 kg Maximum load* (2.25 kg/cm2, (2.90 kg/cm2, handling, braking, performance and
2.25 bar) 2.90 bar)
safety. Do not carry loosely packed
225 kPa 290 kPa
High speed riding (2.25 kg/cm2, (2.90 kg/cm2,
items that can shift. Securely pack
2.25 bar) 2.90 bar) your heaviest items close to the
1. Side wall
* Load is the total weight of cargo, rider, passenger center of the motorcycle, and dis- a. Tread depth
and accessories.
tribute the weight evenly from side Tire inspection
to side. Properly adjust the suspen- Always check the tires before operating
sion for your load, and check the the motorcycle. If center tread depth
condition and pressure of your tires. reaches the limit as shown, if the tire
NEVER OVERLOAD YOUR MOTOR- 6
has a nail or glass fragments in it, or if
CYCLE. Make sure the total weight the side wall is cracked, contact a
of the cargo, rider, passenger, and Yamaha dealer immediately and have
accessories (fairing, saddlebags, the tire replaced.
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000095 EW000080

@
WARNING @
WARNING
Operating the motorcycle with ex- ● After extensive tests, the tires
cessively worn tires decrease riding mentioned below have been ap-
stability and can lead to loss of con- proved by Yamaha Motor Co.,
trol. Have excessively worn tires re- Ltd. for this model. No guaran-
placed by a Yamaha dealer tee for handling characteristics
immediately. Brakes, tires, and relat- can be given if tire combina-
ed wheel parts replacement should tions other than what is ap-
1. Tire valve
be left to a Yamaha Service Techni- 2. Valve core
proved are used on this
cian. 3. Valve cap with seal motorcycle. The front and rear
@

CE-26E Tire information tires should be of the same

Minimum tire tread depth
1.6 mm This motorcycle is equipped with tube- manufacture and design.
(front and rear)
less tires, tire valves and cast wheels. ● The use of tire valves and valve
6 cores other than listed below
NOTE:
@

These limits may be different by regula- could cause tire deflation dur-
tion from country to country. If so, con- ing extreme high speed riding.
form to the limits specified by the Always use genuine parts or
regulations of your own country. their equivalent for replace-
@
ment.
● Be sure to install the valve caps
securely, as these are important
to prevent air pressure leakage
during extreme high speed
riding.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

CE-10E EAU00684 EAU00687
FRONT
Manufacturer Size Type WARNING Wheels
@

Bridgestone 110/70 ZR17 (54W) BT-57F This motorcycle is fitted with super To ensure maximum performance,
Dunlop 110/70 ZR17 (54W) D207F high-speed running tires. The fol- long service, and safe operation, note
Metzeler 110/70 ZR17 (54W) MEZ1 FRONT lowing points must be observed in the following:
Michelin 110/70 ZR17 (54W) MACADAM 90X order for you to make fully effective ● Always inspect the wheels before

REAR use of these tires. a ride. Check for cracks, bends, or

Manufacturer Size Type ● Never fail to use the specified warpage of the wheels. If any ab-
Bridgestone 160/60 ZR17 (69W) BT-57R tires in tire replacement. Other normal condition exists in a wheel,
Dunlop 160/60 ZR17 (69W) D207J tires may have a danger of consult a Yamaha dealer. Do not
Metzeler 160/60 ZR17 (69W) MEZ1
bursting at super high-speeds. attempt even small repairs to the
Michelin 160/60 ZR17 (69W) MACADAM 90X
● New tires have a relatively low wheel. If a wheel is deformed or
CE-12E
grip on the road surface until cracked, it must be replaced.
Type
they have been slightly worn. ● Tires and wheels should be bal-
Tire valve TR412
Therefore, approximately 100 km anced whenever either one is 6
Valve core #9000A (original)
should be traveled at normal changed or replaced. Failure to
speed before any high-speed have a wheel balanced can result
riding is done. in poor performance, adverse han-
● Before any high-speed runs, the dling characteristics, and short-
tires should be warmed-up suf- ened tire life.
ficiently. ● Ride at moderate speeds after

● Always inflate to the correct tire changing a tire since the tire sur-
pressure according to the oper- face must first be broken in for it to
ating conditions. develop its optimal characteristics.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:
@

If proper adjustment cannot be ob-

tained or the clutch does not work cor-
rectly, ask a Yamaha dealer to inspect
the internal clutch mechanism.
@

1. Locknut a. Pedal height

2. Adjusting bolt EAU00712*

c. Free play Rear brake pedal height check

EAU00692
The top of the brake pedal should be
Clutch lever free play
positioned 36.6 mm below the top of
adjustment the footrest. If not, ask a Yamaha deal-
6 The clutch lever free play should be ad- er to adjust it.
justed to 10 ~ 15 mm. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut.
2. Turn the adjusting bolt at the
clutch lever in direction a to in-
crease free play or in direction b
to decrease free play.
3. Tighten the locknut.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000109

@
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the brake system. This air
must be removed by bleeding the
brake system before the motorcycle
is operated. Air in the system will
cause greatly diminished braking
1. Brake light switch
capability and can result in loss of 2. Adjusting nut
control and an accident. Have a EAU00713

Yamaha dealer inspect and bleed Brake light switch adjustment

the system if necessary. The rear brake light switch is activated
@

by the brake pedal and is properly ad-

justed when the brake light comes on 6
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut. Turn the ad-
justing nut in direction a to make the
brake light come on earlier. Turn the
adjusting nut in direction b to make the
brake light come on later.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Wear indicator groove 1. Wear indicator groove 1. Minimum level mark

EAU01314 EAU00731

Checking the front and rear Inspecting the brake fluid

brake pads level
Each brake pad is provided with a wear Insufficient brake fluid may let air enter
6 indicator groove, which allows check- the brake system, possibly causing the
ing the brake pad for wear without dis- brakes to become ineffective.
assembling the brake. Inspect each Before riding, check that the brake fluid
wear indicator groove and, as soon as is above the minimum level and replen-
one of them has almost worn away, ish when necessary.
ask a Yamaha dealer to replace the Observe these precautions:
brake pads as a set. ● When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.

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PERIODIC MAINTENANCE AND MINOR REPAIR

● Be careful that water does not en- EAU00742

ter the master cylinder when refill- Brake fluid replacement

ing. Water will significantly lower The brake fluid should be replaced only
the boiling point of the fluid and by trained Yamaha service personnel.
may result in vapor lock. Have the Yamaha dealer replace the
● Brake fluid may deteriorate paint-
following components during periodic
ed surfaces or plastic parts. Al- maintenance or when they are dam-
ways clean up spilled fluid aged or leaking:
● oil seals (every two years)
immediately.
1. Minimum level mark ● brake hoses (every four years)
● Have a Yamaha dealer check the
● Use only the designated quality
cause if the brake fluid level goes
brake fluid. Otherwise, the rubber
down.
seals may deteriorate, causing
leakage and poor brake perfor-
mance. 6

Recommended brake fluid: DOT 4

● Refill with the same type of brake

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EC000096

CAUTION:
@

Too little chain slack will overload

the engine and other vital parts.
Keep the slack within the specified
limits.
@

3. After adjusting, tighten the lock-

nuts. Then tighten the axle nut to
a. Chain slack 1. Axle nut the specified torque.
EAU00745 2. Chain adjusting nut
Drive chain slack check 3. Locknut
Tightening torque:
4. Alignment marks
EAU00762 Axle nut:
NOTE:
@

Spin the wheel several times and find Drive chain slack adjustment 117 Nm (11,7 m·kg)
6 the tightest position of the chain. Check 1. Loosen the axle nut.
and/or adjust the chain slack while it’s 2. Loosen the locknuts on each side.
in this tightest position. To tighten the chain, turn the chain
@
adjusting nuts in direction a. To
Inspect the drive chain when the motor-
loosen the chain, turn the adjust-
cycle is on the centerstand. Check the ing nuts in direction b and push
slack at the position shown in the illus- the wheel forward. Turn each ad-
tration. Normal slack is approximately
justing nut exactly the same
30 ~ 45 mm. If the slack exceeds amount to maintain correct axle
45 mm, adjust. alignment. There are marks on
each side of the swingarm. Use
these marks to align the rear
wheel.
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU03006 EAU02962 EAU00773

Drive chain lubrication Cable inspection and Throttle cable and grip
The chain consists of many parts which lubrication lubrication
work with each other. If the chain is not EW000112
The throttle twist grip assembly should
maintained properly, it will wear out @
WARNING be greased at the time that the cable is
quickly. Therefore, the chain must be Damage to the outer housing of ca- lubricated, since the grip must be re-
serviced regularly. This service is es- bles may lead to internal rusting and moved to get at the end of the throttle
pecially necessary when riding in dusty interfere with the cable movement. cable. After removing the screws, hold
areas. This motorcycle is equipped Replace damaged cables as soon as the end of the cable up in the air and
with a sealed type chain. Steam clean- possible to prevent unsafe condi- put in several drops of lubricant. With
ing, high-pressure washers, and sol- tions. the throttle grip disassembled, coat the
vents can damage the drive chain, so @

metal surface of the grip assembly with

Lubricate the cables and cable ends. If
do not use these for cleaning it. Use a suitable all-purpose grease.
a cable does not operate smoothly, ask
only kerosene to clean the drive chain.
a Yamaha dealer to replace it.
Wipe it dry, and thoroughly lubricate it 6
with SAE 30 ~ 50W motor oil. Do not
Recommended lubricant:
use any other lubricants on the drive
Engine oil
chain. They may contain solvents that
could damage the sealed chain.
EC000097

CAUTION:
@

Be sure to oil the chain after wash-

ing the motorcycle or riding in the
rain.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU02984 EAU02985 EAU02965

Brake and shift pedal Brake and clutch lever Center and sidestand
lubrication lubrication lubrication
Lubricate the pivoting parts. Lubricate the pivoting parts. Lubricate the pivoting and mating
6 joints.
Recommended lubricant: Recommended lubricant: Check to see that the center and side-
Engine oil Engine oil stand move up and down smoothly.

Recommended lubricant:
Engine oil
EW000114

@
WARNING
If the center and/or sidestand does
not move smoothly, consult a
Yamaha dealer.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00790 EAU02939

Rear suspension lubrication Front fork inspection

Lubricate the pivoting parts. Visual check
EW000115

Recommended lubricant: @
WARNING
Molybdenum disulfide grease Securely support the motorcycle so
there is no danger of it falling over.
@

Check for scratches or damage on the

inner tube and excessive oil leakage
from the front fork.
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake. 6
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098

CAUTION:
@

If any damage or unsmooth move-

ment is found with the front fork,
consult a Yamaha dealer.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01144 EAU01271

Wheel bearings Battery

If there is play in the front or rear wheel This motorcycle is equipped with a
hub or if the wheel does not turn sealed-type battery. Therefore it is not
smoothly, have a Yamaha dealer in- necessary to check the electrolyte or fill
spect the wheel bearings. the battery with distilled water.
● If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
● If the motorcycle is equipped with
EAU00794
optional electrical accessories, the
Steering inspection
battery tends to discharge more
Periodically inspect the condition of the
quickly, so be sure to recharge it
steering. Worn out or loose steering
periodically.
bearings may be dangerous. Place a
6
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115

@
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000116
Battery storage
@
WARNING When the motorcycle is not used for a
Battery electrolyte is poisonous and month or longer, remove the battery,
dangerous, causing severe burns, fully charge it and store it in a cool, dry
etc. It contains sulfuric acid. Avoid place.
contact with skin, eyes or clothing. EC000102

ANTIDOTE: CAUTION:
@

● EXTERNAL: Flush with water. ● Completely recharge the bat-

● INTERNAL: Drink large quanti- tery before storing. Storing a
ties of water or milk. Follow with discharged battery can cause
milk of magnesia, beaten egg, permanent battery damage.
or vegetable oil. Call a physi- ● Use a battery charger designed
cian immediately. for a sealed-type (MF) battery.
● EYES: Flush with water for Using a conventional battery
15 minutes and get prompt charger will cause battery dam- 6
medical attention. age. If you do not have a sealed-
Batteries produce explosive gases. type battery charger, contact
Keep sparks, flame, cigarettes etc., your Yamaha dealer.
away. Ventilate when charging or ● Always make sure the connec-
using in an enclosed space. Always tions are correct when reinstall-
shield your eyes when working near ing the battery.
batteries. KEEP OUT OF REACH OF @

CHILDREN.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EC000103

CAUTION:
@

Do not use fuses of higher amper-

age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire.
@

1. Main fuse 1. Bulb holder cover

2. Spare fuse (× 4) Specified fuses: 2. Connector
3. Ignition fuse Main fuse: 30 A EAU00826

4. Signaling system fuse

Headlight fuse: 20 A Headlight bulb replacement
5. Headlight fuse
Parking/Hazard lights fuse: 10 A This motorcycle is equipped with a
6. Radiator fan fuse
7. Odometer fuse Ignition fuse: 20 A quartz bulb headlight. If the headlight
6 8. Parking/Hazard lights fuse bulb burns out, replace the bulb as fol-
EAU01720*
Signaling system fuse: 20 A
Odometer fuse: 5A lows:
Fuse replacement 1. Remove the headlight connector
The fuse boxes are located under the Radiator fan fuse: 10 A
and the bulb holder cover.
seat. If any fuse is blown, turn off the
main switch and the switch of the circuit
in question. Install a new fuse of speci-
fied amperage. Turn on the switches
and see if the electrical device oper-
ates. If a fuse immediately blows again,
consult a Yamaha dealer.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EC000104

CAUTION:
@

To prevent damage to the following:

● Headlight bulb
Avoid touching the glass part of
the bulb. Keep it free from oil;
otherwise, the transparency of
the glass, life of the bulb, and il-
luminous flux will be adversely
1. Bulb holder 1. Don't touch
affected. If oil gets on the bulb,
2. Unhook the bulb holder and re- 3. Put a new bulb into position and
thoroughly clean it with a cloth
move the defective bulb. secure it in place with the bulb
moistened with alcohol or lac-
EW000119
holder.
WARNING quer thinner.
@
● Headlight lens
Keep flammable products and your 6
• Do not affix any type of tinted
hands away from a bulb while it is
film or stickers to the head-
on, as it is hot. Do not touch a bulb
light lens.
until it cools down.
@ • Do not use headlight bulbs of
wattage higher than speci-
fied.
@

4. Install the bulb holder cover and

reconnect the headlight connec-
tor. If the headlight beam adjust-
ment is necessary, ask a Yamaha
dealer to make that adjustment.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Socket 1. Screw 1. Axle

EAU00858 EAU01095 2. Pinch bolt
Taillight bulb replacement Turn signal light bulb EAU01310

1. Remove the seat. replacement Front wheel removal

EW000122
2. Remove the tool kit. 1. Remove the screw and the lens.
3. To remove the socket, turn it coun- WARNING
6 2. Remove the defective bulb by @

● It is advisable to have a Yamaha

terclockwise. pushing it inward and turning it
4. To remove the defective bulb, turn dealer service the wheel.
counterclockwise.
it counterclockwise. ● Securely support the motor-
3. Install a new bulb by pushing it in-
5. Push a new bulb into the socket cycle so there is no danger of it
ward and turning it clockwise.
and turn it clockwise. falling over.
4. Install the lens and tighten the @

6. Install the socket and turn it clock- screw. 1. Place the motorcycle on the cen-
wise. terstand.
7. Install the tool kit and seat. 2. Loosen the pinch bolt, wheel axle
and calipers bolts.
3. Elevate the front wheel.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Brake hose holder 1. Speed sensor 1. Stopper

2. Plastic clamp EAU01309
3. Install the wheel axle (make sure
3. Caliper bolt (× 2) Front wheel installation the slot in the speed sensor fits
4. Speed sensor
1. Lift up the wheel between the front over the stopper on the front fork
4. Remove the brake hose holders
fork legs. outer tube) and let the motorcycle
and calipers.
2. Install the speed sensor onto the down.
5. Remove the plastic clamp holding 6
wheel hub. Make sure the speed 4. Push down hard on the handle-
the speed sensor lead to the brake
sensor rotor projections are bars several times to check for
cable.
aligned with the notches in the proper fork operation.
NOTE: wheel hub. 5. Install the calipers, caliper bolts
@

Do not depress the brake lever when and brake hose holders. Make
the calipers are off the discs as the sure there is enough gap between
brake pads will be forced shut. the brake pads before installing
@

6. While supporting the speed sen- the calipers onto the brake discs.
sor, remove the axle. Make sure 6. Attach the speed sensor cable to
the motorcycle is properly support- the brake hose with the plastic
ed. clamp.

6-36
 E_5dm_Periodic.fm Page 37 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

7. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torques.

Tightening torque:
Wheel axle:
67 Nm (6.7 m·kg)
Pinch bolt:
20 Nm (2.0 m·kg)
1. Axle nut 1. Caliper bolt (× 2)
Caliper bolt: 2. Chain adjusting nut 2. Brake torque rod nut
40 Nm (4.0 m·kg) 3. Locknut 3. Place the motorcycle on the cen-
EAU01318
terstand.
Rear wheel removal
EW000122
4. Remove the axle nut, caliper bolts
WARNING and caliper.
6 @

5. Loosen the locknuts and chain ad-

● It is advisable to have a Yamaha
justing nuts on each side of the
dealer service the wheel.
swingarm.
● Securely support the motor-
6. Push the wheel forward and re-
cycle so there is no danger of it
move the drive chain.
falling over.
@ 7. Support the caliper bracket, pull
1. Loosen the axle nut and caliper out the wheel axle and remove the
bolts. wheel assembly by pulling it back-
2. Remove the brake torque rod nut wards.
and bolt.

6-37
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PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:
@
6. Tighten the axle nut, caliper bolts
● Do not depress the brake pedal and the brake torque rod nut to the
when the caliper is off the disc as specified torques.
the brake pads will be forced shut.
● You do not have to disassemble Tightening torque:
the chain in order to remove or in- Axle nut:
stall the rear wheel. 117 Nm (11.7 m·kg)
@

Caliper bolt:
40 Nm (4.0 m·kg)
EAU01317
Brake torque rod nut:
Rear wheel installation 23 Nm (2.3 m·kg)
1. Install the caliper bracket and
wheel assembly, then insert the
axle.
6
2. Install and adjust the drive chain.
(See page 6-27 for details about
adjusting the drive chain slack.)
3. Install the brake torque rod bolt
and nut.
4. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
5. Take the motorcycle off the cen-
terstand.

6-38
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01008

Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
6 have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.

6-39
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU02990*

Troubleshooting chart
EW000125

@
WARNING
Never check the fuel system while smoking or in the vicinity of an open flame.
@

1. Fuel
Enough fuel. Go to compression check.
Check if there is fuel
in the fuel tank.
No fuel. Supply fuel. Engine doesn’t start, go to compression check.

2. Compression
There is compression. Go to ignition check.
Use the electric starter.
No compression.
Ask a Yamaha dealer to 6
inspect.

3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start
Wet.
Remove spark spark gap or replace spark plugs. the engine.
plugs and
check electrodes.
Engine doesn’t start, go to battery
Dry. Ask a Yamaha dealer to inspect.
check.

4. Battery Engine turns over

Battery good.
quickly.
Engine doesn’t start, ask a Yamaha
Use the electric starter.
dealer to inspect.
Engine turns over Check connections or
slowly. recharge.

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 E_5dm_Periodic.fm Page 41 Saturday, October 16, 1999 1:47 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

5. Engine overheating
EW000070

@
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown
out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
@

Ask a Yamaha dealer to inspect

Leakage.
and repair the cooling system.
Level is low, check the
cooling system for leakage.
No
Add coolant. (See NOTE.)
Wait until the Check the coolant level in the leakage.
6 engine has cooled. reservoir tank and/or radiator.

Restart the engine. If the engine overheats again, ask a

Level is OK.
Yamaha dealer to inspect and repair the cooling system.

NOTE:
@

If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
@

6-41
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MOTORCYCLE CARE AND STORAGE

Care ................................................................................................... 7-1

Storage............................................................................................... 7-4

7
 E_5dm_Cleaning.fm Page 1 Saturday, October 16, 1999 1:47 PM

MOTORCYCLE CARE AND STORAGE

7-
EAU01516

Care Before cleaning Cleaning

The exposure of its technology makes 1. Cover up the muffler outlet with a After normal use
a motorcycle charming but also vulner- plastic bag. Remove dirt with warm water, a neutral
able. Although high-quality compo- 2. Make sure that all caps and covers detergent and a soft clean sponge,
nents are used, they are not all rust-re- as well as all electrical couplers then rinse with plenty of clean water.
sistant. While a rusty exhaust pipe may and connectors, including the Use a tooth or bottle brush for hard-to-
remain unnoticed on a car, it does look spark plug caps, are tightly in- reach parts. Tougher dirt and insects
unattractive on a motorcycle. Frequent stalled. will come off more easily if the area is
and proper care, however, will keep 3. Remove extremely stubborn dirt, covered with a wet cloth for a few min-
your motorcycle looking good, extend like oil burnt onto the crankcase, utes before cleaning.
its life and maintain its performance. with a degreasing agent and a
Moreover, the warranty states that the brush, but never apply such prod-
vehicle must be properly taken care of. ucts onto seals, gaskets, sprock-
For all these reasons, it is recommend- ets, the drive chain and wheel
ed that you observe the following axles. Always rinse the dirt and
cleaning and storing precautions. degreaser off with water.
7

7-1
E_5dm_Cleaning.fm Page 2 Saturday, October 16, 1999 1:47 PM

MOTORCYCLE CARE AND STORAGE

ECA00010
● Do not use any harsh chemical ● For motorcycles equipped with
CAUTION: products on plastic parts. Be a windshield: Do not use strong
@

● Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as
cleaners, especially on spoked sponges which have been in they will cause dulling or
wheels. If you do use such contact with strong or abrasive scratching. Some cleaning
products for hard-to-remove cleaning products, solvent or compounds for plastic may
dirt, do not leave it on any long- thinner, fuel (gasoline), rust re- leave scratches on the wind-
er than instructed, then thor- movers or inhibitors, brake flu- shield. Test the product on a
oughly rinse it off with water, id, antifreeze or electrolyte. small hidden part of the wind-
immediately dry the area and ● Do not use high-pressure wash- shield to make sure they do not
apply a corrosion protection ers or steam-jet cleaners since leave any marks. If the wind-
spray. they cause water seepage and shield is scratched, use a quali-
● Improper cleaning can damage deterioration in the following ar- ty plastic polishing compound
windshields, cowlings, panels eas: seals (of wheel bearings, after washing.
and other plastic parts. Use swingarm bearings, forks and @

only a soft, clean cloth or brakes), electric components

After riding in the rain, near the sea or
sponge with mild detergent and (couplers, connectors, instru- 7
on salt-sprayed roads
water to clean plastic. ments, switches and lights),
Since sea salt or salt sprayed on the
breather hoses and vents.
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

7-2
 E_5dm_Cleaning.fm Page 3 Saturday, October 16, 1999 1:47 PM

MOTORCYCLE CARE AND STORAGE

1. Clean your motorcycle with cold After cleaning EWA00001

water and soap after the engine 1. Dry the motorcycle with a chamois @
WARNING
has cooled down. or an absorbing cloth. Make sure that there is no oil or wax
ECA00012
2. Immediately dry the drive chain on the brakes and tires. If neces-
CAUTION: and lubricate it to prevent it from sary, clean the brake discs and lin-
@

Do not use warm water since it in- rusting. ings with a regular brake disc
creases the corrosive action of the 3. Use a chrome polish to shine cleaner or acetone, and wash the
salt. chrome, aluminum and stainless- tires with warm water and mild soap.
@

steel parts, including the exhaust Then, carefully test the motorcycle
2. Be sure to apply a corrosion pro-
system. (Even the thermally in- for its braking performance and cor-
tection spray on all (even chrome-
duced discoloring of stainless- nering behavior.
and nickel-plated) metal surfaces @

steel exhaust systems can be re-

to prevent corrosion.
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even chrome-
7 and nickel-plated) metal 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 it or covering it.

7-3
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MOTORCYCLE CARE AND STORAGE

ECA00013
Storage Long-term
CAUTION: Short-term Before storing your motorcycle for sev-
@

● Apply spray oil and wax spar- Always store your motorcycle in a cool, eral months:
ingly and wipe off any excess. dry place and, if necessary, protect it 1. Follow all the instructions in the
● Never apply oil or wax on rub- against dust with a porous cover. “Care” section of this chapter.
ber and plastic parts, but treat ECA00014 2. Drain the carburetor float cham-
them with a suitable care prod- CAUTION: bers by loosening the drain bolts;
@

uct. ● Storing the motorcycle in a this will prevent fuel deposits from
● Avoid using abrasive polishing poorly ventilated room or cover- building up. Pour the drained fuel
compounds as they wear away ing it with a tarp while it is still into the fuel tank.
the paint. wet will allow water and humidi- 3. Only for motorcycles equipped
with a fuel cock which has an
@

ty to seep in and cause rust.

NOTE:
@ ● To prevent corrosion, avoid “OFF” position: Turn the fuel cock
Consult a Yamaha dealer for advice on damp cellars, stables (because to “OFF”.
what products to use. of the presence of ammonia) 4. Fill up the fuel tank and add fuel
@

and areas where strong chemi- stabilizer (if available) to prevent

cals are stored. the fuel tank from rusting and the 7
@
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.

7-4
 E_5dm_Cleaning.fm Page 5 Saturday, October 16, 1999 1:47 PM

MOTORCYCLE CARE AND STORAGE

c. Install the spark plug caps onto the 7. Check and, if necessary, correct
spark plugs and place the spark the tire air pressure, then raise the
plugs on the cylinder head so that motorcycle so that both of its
the electrodes are grounded. (This wheels are off the ground. Alterna-
will limit sparking during the next tively, turn the wheels a little every
step.) month in order to prevent the tires
d. Turn the engine over several times from becoming degraded in one
with the starter. (This will coat the spot.
cylinder walls with oil.) 8. Cover up the muffler outlet with a
e. Remove the spark plug caps from plastic bag to prevent moisture
the spark plugs, install the spark from entering.
plugs and then the spark plug 9. Remove the battery and fully
caps. charge it. Store it in a cool, dry
EWA00003
place and recharge it once a
@
WARNING month. Do not store the battery in
When turning the engine over, be an excessively cold or warm place
7 sure to ground the spark plug elec- (less than 0°C or more than 30°C).
trodes to prevent damage or injury For more information, see “Battery
from sparking. storage” in the chapter “PERIOD-
@

6. Lubricate all control cables and IC MAINTENANCE AND MINOR

the pivoting points of all levers and REPAIRS”.
pedals as well as of the sidestand/ NOTE:
@

centerstand. Make any necessary repairs before

storing the motorcycle.
@

7-5
E_5dm_SpecTOC.fm Page 1 Saturday, October 16, 1999 1:47 PM

SPECIFICATIONS

Specifications ..................................................................................... 8-1

HOW TO USE THE CONVERSION TABLE ....................................... 8-5

8
 E_5dm_Spec.fm Page 1 Saturday, October 16, 1999 1:48 PM

SPECIFICATIONS
8-
EAU01038

Specifications
CS-01E
Model FZS600/FZS600SP Engine oil
Dimensions Type
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C
Overall length 2,080 mm (except for N, SF)
2,175 mm (for N, SF) SAE 10W/30

Overall width 710 mm SAE 10W/40

Overall height 1,170 mm SAE 15W/40

Seat height 790 mm SAE 20W/40
Wheelbase 1,415 mm
SAE 20W/50
Ground clearance 130 mm
Minimum turning radius 2,900 mm Recommended engine oil
classification API Service SE, SF, SG type or
Basic weight (with oil and full higher
fuel tank) 210 kg
Engine CAUTION:
Engine type Liquid-cooled 4-stroke, DOHC Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
Cylinder arrangement Forward-inclined parallel “Energy Conserving”) contain anti-friction additives which
4-cylinder will cause clutch and/or starter clutch slippage, resulting in
8 Displacement 599 cm3 reduced component life and poor engine performance.
Bore × Stroke 62.0 × 49.6 mm
Quantity
Compression ratio 12:1
Periodic oil change 2.5 L
Starting system Electric starter
With oil filter replacement 2.7 L
Lubrication system Wet sump
Total amount 3.5 L

8-1
E_5dm_Spec.fm Page 2 Saturday, October 16, 1999 1:48 PM

SPECIFICATIONS
Cooling system total amount 1.95 L Number of drive chain
sprocket teeth (rear/front) 48/15
Air filter Dry type element
Fuel Transmission type Constant mesh 6-speed
Operation Left foot operation
Type Regular unleaded gasoline
Gear ratio
Fuel tank capacity 20 L
Fuel reserve amount 3.5 L 1st 2.846
2nd 1.947
Carburetor
3rd 1.545
Type × quantity BSR33 × 4
Manufacturer MIKUNI 4th 1.333
5th 1.190
Spark plug
6th 1.074
Manufacturer/Type
Except for D, F NGK / CR8E, CR9E or Chassis
DENSO / U24ESR-N, U27ESR-N Frame type Double cradle
For D, F NGK / CR7E, CR8E, CR9E or Caster angle 24°
DENSO / U22ESR-N,
Trail 88 mm
U24ESR-N, U27ESR-N
Tires
Gap 0.7 ~ 0.8 mm
Front
Clutch type Wet, multiple-disc
Type Tubeless 8
Transmission
Size 110 / 70 ZR17 (54W)
Primary reduction system Spur gear
Manufacturer/
Primary reduction ratio 1.708 model Bridgestone / BT-57F
Secondary reduction system Chain drive
Dunlop / D207F
Secondary reduction ratio 3.200
Metzeler / MEZ1 FRONT
Michelin / MACADAM 90X

8-2
 E_5dm_Spec.fm Page 3 Saturday, October 16, 1999 1:48 PM

SPECIFICATIONS
Rear Rear
Type Tubeless Type Cast
Size 160 / 60 ZR17 (69W) Size 17 × MT 5.00
Manufacturer/ Brakes
model Bridgestone / BT-57R
Front
Dunlop / D207J Type Dual disc brake
Metzeler / MEZ1
Operation Right hand operation
Michelin / MACADAM 90X
Fluid DOT 4
Maximum load* 187 kg Rear
Air pressure (cold tire)
Type Single disc brake
Up to 90 kg load*
Operation Right foot operation
Front 225 kPa (2.25 kg/cm2, 2.25 bar) Fluid DOT 4
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
Suspension
90 kg load ~ maximum Front
load*
Type Telescopic fork
Front 225 kPa (2.25 kg/cm2, 2.25 bar)
Rear
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
Type Swingarm (link suspension)
8 High speed riding
Shock absorbers
Front 225 kPa (2.25 kg/cm2, 2.25 bar)
Front Coil spring / oil damper
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
Rear Coil spring / gas-oil damper
* Load is total weight of cargo, rider, passenger and accessories.
Wheel travel
Wheels
Front 120 mm
Front
Rear 120 mm
Type Cast
Size 17 × MT 3.00

8-3
E_5dm_Spec.fm Page 4 Saturday, October 16, 1999 1:48 PM

SPECIFICATIONS
Electrical system Fuses
Ignition system T.C.I. (digital) Main fuse 30 A
Charging system Headlight fuse 20 A
Type A.C. magneto Signaling system fuse 20 A
Standard output 14 V, 18 A @ 5,000 r/min Ignition fuse 20 A
Battery Radiator fan fuse 10 A
Type GT12B-4 Parking/Hazard lights fuse 10 A
Voltage, capacity 12 V, 10 AH Odometer fuse 5A
Headlight type Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
12 V, 55 W × 1
Auxiliary light 12 V, 5 W × 1
Tail/brake light 12 V, 5/21 W × 2
Turn signal light 12 V, 21 W × 4
Meter light 12 V, 2 W × 3
Neutral indicator light 14 V, 1.4 W × 1
8
High beam indicator light 14 V, 1.4 W × 1
Oil level indicator light 14 V, 1.4 W × 1
Turn indicator light 14 V, 1.4 W × 2
Fuel indicator light 12 V, 2 W × 1
Coolant temperature indicator
light LED

8-4
 E_5dm_Spec.fm Page 5 Saturday, October 16, 1999 1:48 PM

SPECIFICATIONS
EAU01064

HOW TO USE THE CONVERSION TABLE

CS-02E
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC TO IMPERIAL
METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb
m·kg 86.794 in·lb
unit data. Torque
cm·kg 0.0723 ft·lb
Ex. cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
METRIC MULTIPLIER IMPERIAL g 0.03527 oz
Speed km/hr 0.6214 mph
**mm × 0.03937 = **in
km 0.6214 mi
m 3.281 ft
2 mm × 0.03937 = 0.08 in Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume / cc (cm3) 0.06102 cu·in
Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm2 14.2234 psi (lb/in2)
8 Centigrade (°C) 9/5 + 32 Fahrenheit (°F)

8-5
E_5dm_ConsumerTOC.fm Page 1 Saturday, October 16, 1999 1:48 PM

CONSUMER INFORMATION

Identification number records............................................................. 9-1

Key identification number ................................................................... 9-1
Vehicle identification number.............................................................. 9-1
Model label......................................................................................... 9-2

9
 E_5dm_Consumer.fm Page 1 Saturday, October 16, 1999 1:48 PM

CONSUMER INFORMATION
9-
EAU01039

EAU02944

Identification number records

Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION NUMBER: 1. Key identification number 1. Vehicle identification number
CA-02E EAU01041 EAU01043

Key identification number Vehicle identification number

The key identification number is The vehicle identification number is
stamped on the key tag. Record this stamped into the steering head pipe.
2. VEHICLE IDENTIFICATION number in the space provided and use Record this number in the space pro-
NUMBER: it for reference when obtaining a new vided.
CA-02E key.
NOTE:
@

The vehicle identification number is

used to identify your motorcycle and
may be used to register your motor-
3. MODEL LABEL INFORMATION: cycle with the licensing authority in
9 CA-01E
your state.
@

9-1
E_5dm_Consumer.fm Page 2 Saturday, October 16, 1999 1:48 PM

CONSUMER INFORMATION

1. Model label
EAU01050

Model label
The model label is affixed to the frame
under the seat. (See page 3-14 for seat
removal procedures.) Record the infor-
mation on this label in the space pro-
vided. This information will be needed
to order spare parts from your Yamaha
dealer.

9-2
E_5dmIX.fm Page 1 Saturday, October 16, 1999 1:48 PM

INDEX
10-

A E Helmet holder.........................................3-15
Air filter ..................................................6-15 Engine break-in ....................................... 5-5 High beam indicator light..........................3-3
Antitheft alarm (optional) ..........................3-8 Engine oil ................................................ 6-9 Horn switch ..............................................3-9
Engine stop switch................................. 3-10 I
B
Battery ...................................................6-31 F Identification number records ...................9-1
Brake and clutch lever lubrication...........6-29 Front brake lever ................................... 3-11 Idle speed adjustment ............................6-18
Brake and shift pedal lubrication ............6-29 Front fork adjustment............................. 3-16 Indicator lights..........................................3-3
Brake fluid replacement .........................6-26 Front fork inspection .............................. 6-30 Coolant temperature indicator light .....3-3
Brake light switch adjustment.................6-24 Front wheel installation .......................... 6-36 Fuel indicator light...............................3-3
Front wheel removal .............................. 6-35 High beam indicator light ....................3-3
C Neutral indicator light ..........................3-3
Fuel ....................................................... 3-13
Cable inspection and lubrication ............6-28
Fuel gauge .............................................. 3-8 Oil level indicator light .........................3-3
Carburetor adjustment ...........................6-18
Fuel indicator circuit check....................... 3-5 Turn indicator lights ............................3-3
Care.........................................................7-1 Inspecting the brake fluid level ...............6-25
Fuel indicator light ................................... 3-3
Center and sidestand lubrication............6-29
Fuel tank breather hose......................... 3-13 K
Changing the coolant .............................6-13
Fuel tank cap......................................... 3-12
Checking the front and Key identification number .........................9-1
Fuse replacement.................................. 6-33
rear brake pads ...................................6-25 L
Clutch lever............................................3-10 G Left view...................................................2-1
Clutch lever free play adjustment ...........6-23 Give safety the right of way ..................... 1-1
Lights switch ..........................................3-10
Controls/Instruments................................2-3 Luggage strap holders ...........................3-17
H
Coolant temperature indicator light...........3-3
Handlebar switches ................................. 3-9 M
Cooling system ......................................6-12
Dimmer switch ................................... 3-9
Main switch/Steering lock.........................3-1
D Engine stop switch ........................... 3-10
Model label ..............................................9-2
Diagnosis device......................................3-7 Hazard switch .................................... 3-9
Dimmer switch .........................................3-9 Horn switch ........................................ 3-9 N
Drive chain lubrication............................6-28 Lights switch .................................... 3-10 Neutral indicator light ...............................3-3
Drive chain slack adjustment..................6-27 Pass switch ........................................ 3-9 O
Drive chain slack check..........................6-27 Start switch ...................................... 3-10
Oil level indicator circuit check .................3-4
Turn signal switch .............................. 3-9
Oil level indicator light ..............................3-3
Hazard switch.......................................... 3-9
Headlight bulb replacement ................... 6-33
E_5dmIX.fm Page 2 Saturday, October 16, 1999 1:48 PM

INDEX
P Steering inspection................................ 6-31
Panel A, C ............................................... 6-5 Storage ................................................... 7-4
Panel B.................................................... 6-6 Storage compartment............................ 3-15
Panel removal and installation ................. 6-5 T
Parking .................................................... 5-6 Tachometer............................................. 3-7
Pass switch ............................................. 3-9
Taillight bulb replacement ..................... 6-35
Periodic maintenance and lubrication ...... 6-2
Throttle cable and grip lubrication.......... 6-28
Pre-operation check list ........................... 4-1 Throttle cable free play inspection ......... 6-19
R Tips for reducing fuel consumption.......... 5-5
Rear brake pedal ................................... 3-11 Tires...................................................... 6-19
Rear brake pedal height check .............. 6-23 Tool kit .................................................... 6-1
Rear shock absorber adjustment ........... 3-17 Troubleshooting .................................... 6-39
Rear suspension lubrication................... 6-30 Troubleshooting chart ........................... 6-40
Rear wheel installation........................... 6-38 Turn indicator lights................................. 3-3
Rear wheel removal............................... 6-37 Turn signal light bulb replacement......... 6-35
Recommended shift points Turn signal switch ................................... 3-9
(for Switzerland only)............................. 5-5 V
Right view................................................ 2-2
Valve clearance adjustment .................. 6-19
S Vehicle identification number................... 9-1
Seat....................................................... 3-14 W
Shifting .................................................... 5-4
Wheel bearings ..................................... 6-31
Shift pedal ............................................. 3-11
Wheels.................................................. 6-22
Sidestand .............................................. 3-18
Sidestand/clutch switch operation
check .................................................. 3-19
Spark plugs ............................................. 6-7
Specifications .......................................... 8-1
Speedometer........................................... 3-6
Starter (choke) “ ” ............................... 3-14
Starting a warm engine............................ 5-4
Starting the engine .................................. 5-1
Start switch............................................ 3-10
 YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
99 · 10 - 0.3 × 1 CR
(E)