YAMAHAINTRODUCTION Welcome to the Yamaha world of motorcycling! {As the owner of the TDM800, you are benefiting from Yamaha's vast experience and newest technology regarding the de- sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependably Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM900. 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 ties given in this manual wall help keep your motorcycle in the best possible condition If you have any further questions, do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So, remember to put safety first!IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: Bw The Safety Alert Symbol means ATTENTION! BECOME ALEATI YOUR SAFETY IS INVOLVED! PWG Failure to follow WARNING instructions could result in severe injury or death to the motorcy- cle operator, a bystander, or @ person inspecting or repairing tho motoroycle. a "A CAUTION indicates special precautions that must be taken to avold damago To the motor — cycle. NOTE: ANOTE provides key information to make procedures easter or clearer NOTE: © This manual should be considered a permanent part of this motorcycle and should remaun with even if the motoroycle 's 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 betwaen your motoreycle and this manual If you have any questions concerning this manual, please consult your Yamaha dealer PN PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.IMPORTANT MANUAL INFORMATION ToMS00S OWNERS MANUAL ©2003 by Yamaha Motor Co., Ltd. Ast edition, July 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.TABLE OF CONTENTS SAFETY INFORMATION Location of important labels DESCRIPTION Left view Right view Controls and instruments INSTRUMENT AND CONTROL, FUNCTIONS. Immobilizer system Main switchisteering lock Indicator and warning ights Speedometer unit Tachometer unt Coolant temperature gauge Anti-theft alarm (optional) Handlebar switches Clutch lever Shift pedal Brake lever Brake pedal Fuel tank cap Fuel Catalytic converter Seat Storage compartment ‘Adjusting the front fork Adjusting the shock absorber assembly Luggage strap holders Bat 342. 343 B13 314 a4 348 347 Sidestand Ignition creutt cutoff system PRE-OPERATION CHECKS. re-operation check list, OPERATION AND IMPORTANT RIDING POINTS Starting the engine Shifting Tips for reducing fuel consumption Engine breakin Parking PERIODIC MAINTENANCE AND MINOR REPAIR ‘Owner's tool kit Penodic maintenance and lubrication chart Removing and installing cowings and panels Checking the spark plugs Engine oil and ot fiter element Coolant Replacing the ar fiter element Adjusting the engine sing speed BIT 318 at 42 SA St 52 53 53 54 et et 610 614 615 Adjusting the throtta cable free play ‘Aduusting the valve clearance Tires Cast wheels Adjusting the clutch lever free play Adjusting the brake pedal position 7 Adjusting the rear brake light ssvatch Checking the front and rear brake pads Checking the brake fluid level ‘Changing the brake fluid Drive chain slack Lubricating the dave chain (Checking and lubricating the ‘cables ‘Checking and lubneating the throttle gup and cable (Checking and lubricating the brake and shift pedals Checking and lubricating the brake and ciuteh levers ‘Checking and lubricating the sidestand Lubricating the rear ‘suspension e168 646 616 619 6-20 eat 621 622 6:28 624 6:25 626TABLE OF CONTENTS ‘Checking the front fork ‘Checking the steering ‘Checking the wheel bearings Batiery Replacing the fuses Replacing a headlight bulb Replacing the tatlbrake light bulb Replacing a tum signal light bulb ‘Supporting the motorcycle Front wheel Rear wheel Troubleshooting ‘Troubleshooting charts MOTORCYCLE CARE AND STORAGE Care Storage SPECIFICATIONS. CONSUMER INFORMATION Identification numbers Motorcycle noise regulaton (for Australia)4) SAFETY INFORMATION MOTORCYCLES ARE — SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN- DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA TOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MO- TORCYCLE HE OR SHE SHOULD: @ OBTAIN THOROUGH INSTRUC- TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. @ OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE- MENTS IN THE OWNER'S MAN: UAL © OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES © OBTAIN PROFESSIONAL TECH- NICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECES- ‘SARY BY MECHANICAL CONDI- TIONS Safe riding ‘© Always make —_pre-operation checks Careful checks may help prevent an accident ‘© This motorcycle s designed to car- ry the operator and a passenger. © The failure of motonssts to detect and recognize motorcycles in traf fic 1s the predominating cause of automobile/motorcycle accidents Many aceents have been caused by an automobile drver who old not see the motorcycle, Making yourself conspicuous appears to be very effective in reducing the chanee of this type of accident. © Therefore: + Wear a brightly colored jacket + Use extra caution when you are approaching and passing through intersections, since in- tersections are the most likely places for motorcycle accidents to occur 4s + Ride where other motorists can see you. Avoid riding in another motonst's blind spot Many accidents involve expen: enced operators In fact, many op- erators who have been involved in accidents do not even have a cur- rent motorcycle license + Make sure that you are qualified and that you oniy lend your mo- torcycle to other quaiified opera- tors + Know your skills and limits Staying within your limits may help you to avoid an accident + We recommend that you prac- toe riding your motoraycle where there Is no traffic until you have become thoroughly faril- tar with the motorcycle and all of its controls. Many accidents have been caused by error of the motorcycle opera- tor A typical error made by the op- erator 1s veenng wide on a turn due to EXCESSIVE SPEED or un-4 SAFETY INFORMATION dercomering (insufficient lean an- gle for the speed), «+ Always obey the speed hit and never travel faster than warrant- ed by road and traffic conditions «+ Always signal before turning or changing lanes Make sure that other motonsts can see you. The posture of the operator and passenger 1s important for proper control « The operator should keep both hands on the handlebar and both feet on the operator foot- rests during operation to main- tain contol of the motorcycle + The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. + Never carty a passenger unless he or she can firmiy place both feet on the passenger footrests Never nide under the influence of alcohol or other drugs. ‘© This motorcycle 1s designed for on-road use only Its not suitable for offroad use. Protective apparel The majority of fatalities from motorcy- le acoidents are the result of head in- juries The use of a safety helmet is the single most entical factor in the preven tion oF reduction of head injuries © Always wear an approved helmet. © Wear a face shield or goggles. Wind in your unprotected eyes could contnbute to an impairment of vision that could delay seeing a hazard © The use of a jacket, heavy boots, trousers, gloves, etc, isetfective in preventing or reducing abrasions of lacerations © Never wear loose-fiting clothes, ‘otherwise they could catch on the control levers, footrests, or wheels and cause injury oF an accident @ Never touch the engine or exhaust system dunng or after operation. They become very hot and can 12 cause bums Always wear protec: ‘ive clothing that covers your legs, ankles, and feet. ‘© A passenger should also observe the above precautions, Modifications Modifications made to this motorcycle not approved by Yamaha, or the re- moval of otiginal equioment, may ren- der the motorcycle unsafe for use and may cause severe personel injury. Modifications may also make your mo- torcycie illegal to use Loading and accessories Adding accessories of cargo to your motorcycle can adversely affect stabil- ty and handling ifthe weight distrbuton of the motorcycle is changed, To avoid the possiblity of an accident, use ex- treme caution when adding cargo or accessories 10 your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to {ollow if loading cargo or adding acces: sortes to your motorcycle2\ SAFETY INFORMATION Loading The total weight of the operator, pas- senger, accessones and cargo must not exceed the maximum load limit of 208 kg (448 Ib) When loading within this weight limit, Keep the following in ming @ Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as eveniy as possible on both sides of the motorcycie to minimize imibal- ance or instability. ‘© Shifting weights can create a sud- den imbalance Make sure that ac- cessones and cargo are securely attached to the motorcycle before nding. Check accessory mounts and cargo restraints frequently © Never attach any large or heavy ttems to the handlebar, front fork, ‘or front fender These items, in- cluding such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response Accessories Genuine Yamaha accessones have been specificaly designed for use on thss motorcycle Since Yamaha cannot test all other accessones that may be available, you must personally be re- sponsible for the proper selection, in- stallation and use of non-Yamaha accessones Use extreme caution when selecting and installing any ac- cessories. Keep the following guidelines in ming, {as well as those provided under “Load- ng” when mounting accessories. Never install accessones or carry ‘cargo that would impair the perfor- mance of your motorcycle, Care- fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limt suspension travel, steering travel or control operation, or ob- soure lights or reflectors + Accessories fited to the handle: 13 bar or the front fork area can create instability due to improper weight distnbution or aerody- namic changes If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. Bulky or large accessories may seriously affect the stabiity of the motoreycle due to aerody- namic effects Wind may at- tempt to ltt the motorcycle, or the motorcycle may become un- stable in cross wands. These ac- cessones may also cause instability when passing or being passed by large vehicles Certain accessones can dis- Place the operator from his or her norma! nding position. This improper position limits the free- dom of movement of the opera tor and may limit control absity, therefore such accessones are not recommended2 SAFETY INFORMATION ‘@ Use caution when adding elect ——leaving the motorcycle unattended ——ly_‘If any gasoline spills on your calaccessones Ifelectncal acces- -andremove the key ffom the main _skmn or clothing, immediately wash sones exceed the capacity of the switch, When parking the motorcy- the affected area with soap and motorcycle’s electncal system an _—_cle, note the followang’ water and change your clothes ‘electric failure could result, which «The engine and exhaust system i could cause a dangerous loss of may be hot, therefore, park the lights or engine power motorcycle na place where pe- Gasoline and exhaust gas destnans or children are not lke ‘© GASOLINE IS HIGHLY FLAMMA- ly to touch these hot areas BLE + Do not park the motorcycle on a + Always tum the engine off when slope or soft ground, otherwase it refueling may fall over + Take cate not to spill any gaso- «Do not park the motoreycle near line on the engine or exhaust aflammable source, (2.g., aker- system when refueling osene heater, or near an open «+ Never refuel while smoking or in flame), otherwise tt could catch the vicinity of an open flame fire © Never start the engine or let trun @ When transporting the motorcycle for any length of time ma closed in another vehicle, make sure that area The exhaust fumes are po its kept upright If the motorcycle sonous and may cause loss of should lean over, gasoline may consciousness and death within a leak out of the fuel tank short time. Always operate your @ If you should swallow any gaso- motorcycle nan area that has ad- line, mhale a lot of gasoline vapor, equate ventilation or allow gasoline to get into your © Always turn the engine off before eyes, see your doctor immediate- +42) SAFETY INFORMATION Location of important labels Please read the following important labels carefully before operating this vehicle.4 SAFETY INFORMATIONDESCRIPTION Left view 4 1. Front fork spring preload adjusting bolt (page 3-14) 2 Front fork damping adjusting screw (page 3-14) 3 Arter element (page 6-14) 4 Shock absorber assembly compression damping force adjusting knob (page 3-15) 5 Battery (page 6-29) 6 Fuses (page 6:00) 7 Storage compartment ipage 3-14) 13121110 9 9 8 Grab bar 9 Luggage strap holder (page 3-17) 10 Seat loc (page 9-13} 11 Shock absorber assembly rebound damping force adjusting knob (page 315) 12 Stock absorber assemaly sorng preload aqjsstng ang (page 2-15) 13 Shut pedal (page 3-10) 14 Engine ol rain bait A (page 6-7)Right view 1 Owners tool kt (page 6-1) 2 Coolant racarvor (page 6-19) 28 Tarotle stop serew (page 6-15) 4 Front brake fd reservar (page 6-22) 5 Radiator cap (pave 6-10) 6 Engine oi filet cap (page 6-7) ‘element (page 6-7) m bolt B (page 6-7) DESCRIPTION Brake pedal (page 3-11) 40 Rear brake fluid reservor (page 6-22)DESCRIPTION Controls and instruments 1 Clutch lever (page 3-9) 2 Left andlebar suntehes (page 2-2) 3 Speedometer unt (page 2-5} 4 Man ewichisteering lock (page $2) 5 Tachometer unt (page 26) 6 Coolant temperature gauge (page 3-7) 7 Right handlebar swiches (page 38) 8 Brake over (page 3-10} 2 89 9 Throttle anp (page 6-16) 23INSTRUMENT AND CONTROL FUNCTIONS Immobilizer system at ‘ + Code reregstenng Key (60 Bow) 2 Standa keys (back bow) This vehicle 1s equipped with an immo- biizer system to help prevent theft by re-registenng codes in the standard keys This system consists of the fok towing. © a code re-segistering key (with 2 red bow) ‘© two standard keys (with a black bow) that can be re-registered with new codes © a transponder (which is installed in the code re-registening key) © an immobilizer unit © the ECU © an immobilizer system indicator light (See page 3-3.) The key with the red bow 1s used to reg- ister codes in each standard key. Since re-registering is a dificult process, take the vehicle along with all three keys to a Yamaha dealer to have them re-teg- istered. Do not use the key with the red bow for driving. It should only be used for re-registering the standard keys Al- ways use a standard key for driving. jCAUTIONE @ DO NOT LOSE THE CODE RE-REGISTERING KEY! CON- TACT YOUR DEALER IMMEDI- ATELY IF IT IS LOST! If the code re-rogistering key is lost, regis- tering new codes in the stan- dard keys is impossible. The standard keys can still be used to start the vehicle, however if code re-registering is required . if a new standard key is made or all keys are lost) the en- tire immobilizer system must be replaced. Therefore, it is highly a recommended to use either standard key and keep the code re-vegistering key in a safe place. Do not submerse any key in wa- ter. Do not expose any key to exces sively high temperatures. Do not place any key close to magnets (this includes, but not limited to, products such as speakers, etc.). Do not place heavy items on any key. Do not grind any key or alter its shape. Do not disassemble the plastic part of any key. Do not put two keys of any im- mobilizer system on the same key ring. Keep the standard keys as well as keys of other immobilizer systems away from this vehi- cle’s code re-registering key. Keep other immobilizer systemINSTRUMENT AND CONTROL FUNCTIONS keys away from the main switch as they may cause signal inter- ferenc Main switch/steering lock OFF ON The main switch/steenng lock controls the ignition and lighting systems, and is used to lock the steering NOTE: Be sure to use the standard key (black bow) for regular use of the vehicle To Minimize the nsk of losing the code re-registering key (ced bow), keep tina sale place and only use tt for code re-registenng on All electrical circuits are supplied with power, the meter lighting, tailight and auxiliary light come on, and the engine can be started The key cannot be re: 32 moved. NOTE: The headlight comes on automatically when the engine is started and stays on Until the key is turned to “OFF” OFF All electrical systems are off. The key can be removed Lock ‘The steering is locked, and all electrical systems are off The key can be re- moved ‘Tolack the steenng 1 Push 2 Tun ‘Tum the handlebars all the way to theINSTRUMENT AND CONTROL FUNCTIONS left or nght 1 Push the key in from the “OFF” po- sition, and then turn it to "LOCK" ‘while stil pushing it 2. Remove the key ‘Tounlock the steenng 1 Push 2 Tun Push the key into the main switch, and then turn if to “OFF” while still pushing it ae Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems wi be switched off, which may result in Joss of control or an accident, Make sure that the vehicle is stopped be- fore turning the key to “OFF” or “Loci P¢ (Parking) ‘The steering is locked, and the tailight and auxilary light are on The hazard light and tur signal ights can be turned on, but all other electncal systems are off The key can be removed, The steering must be locked before the key can be turned to "Pe", caution: Do not use the parking position for an extended length of time, other- wise the battery may discharge. Indicator and warning lights 2345678 1 Fuel level warning ight "i 2 Lett tur signal indicator ight "<>" 3 High beam indicator ight" D" 4 Neutral inteator ight“ NN" 45 Engine trouble warning ight ">" 6 Fight turn signal mdicator ight ">" 7 Oi level warring ight" {8 Immobiizer system ndicator baht” Turn signal indicator lights “ TRIP 1 + TRIP 2 ODO > TRIP F To reset a tnpmeter, select it by push-INSTRUMENT AND CONTROL FUNCTIONS Ing the "SELECT" button, and then push the “RESET” button. if you do not reset the fuel reserve tripmeter manual- ly, it will reset itself automatically and the display will return to “TRIP 1” after refueling and traveling 5 km (3 mi). ore: EEE eee Alter resetting the fuel reserve tripme- ter, the display will return to “TRIP 1”, unless a different mode had been pre- viously selected; in that case, the dis- play automateally returns to the prior mode Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The display seg- ments of the fuel gauge disappear to- wards “E” (Empty) as the fuel level decreases. When only one segment is leftnear*E", refuel as soon as possible Self-diagnosis device This model is equipped with a self-ctag- nosis device for various electrical courts Ifany of those circutts are defective, the ‘odometeritriometer will indicate a two-digit error code (eg, 11, 12, 13) If the odometeritipmeter indicates such an ertor code, note the code num- ber, and then have a Yamaha dealer check the vehicle an error code, the vehicle should be checked as soon as possible in or- der to avoid engine damage. 36 Tachometer unit 1 Tachometer 2 Tachomoter red zone 3 Clock ‘The electnc tachometer allows the nder ‘tomonitor the engine speed and keep tt vnthin the ideal power range, ‘When the key is turned to “ON”, the tachometer needle will move to 9500 timin and back to zero r/min in order to test the electncal circuit Scaution# Do not operate the engine in the ta- chometer red zone. Red zone: 8000 r/min and above This tachometer units equipped with aINSTRUMENT AND CONTROL FUNCTIONS clock. cane aga To set the clock Coolant temperature gauge ——_IcauTIONE, 1 Push both the “SELECT” and “RE- SO Do not operate the engine it it is SET" buttons for atleast Wo sec: NY Ses overheated. onds os 6 7 2 When the hourdigits start flashing, §—§ LCS ) (7 A\\ push the “RESET” button to set the YY) fe N\\\ hours a) | 8 Push the “SELECT” button to = As ee) ‘change the minutes. a SZ, 4, When the minute digits start flash- ing, push the "RESET" button to set the minutes 5 Push the “SELECT” button to start the clock NOTE: © After setting the clock, be sure to push the “SELECT” button before ‘uring the key to“OFF", otherwise the clock will not be set. © When the key is tured to "OFF", the clock display will remain on for 48 hours and then go off o prevent the battery from discharging, 1 Coolant tempereture gauge 2 Coolant empereture gauge red zone With the key in the "ON" position, the coolant temperature gauge indicates the temperature of the coolant When the key 1S turned to “ON’, the coolant temperature gauge needle will move to “H” and back to "C” in order to test the electncal circut The coolant tempera- ture varies with changes in the weather and engine load I the needle reaches ‘or enters the red zone, stop the vehicle and let the engne cool. (See page 6-39) a7INSTRUMENT AND CONTROL FUNCTIONS Anti-thett alarm (optional) This model can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information Handlebar switches Left 1 Pass satch +30" 2 Hazara swch “a.” 4 Tuen signal sutch "2/2" 5 Hoan sath * pe 38 Right 1 Engine stop saiton "5%" 2 Startamich *@" Pass switch “20” Press this switch to flash the headlight. Dimmer switch “0/30” Set this switch to "sD" for the high beam and to “s0" for the low beam ‘Tum signal switch “” To signal a nght-hand turn, push this switch to “=>” To signal a left-hand ‘tur, push this switch to"<>” When re- leased, the swntch returns to the center positon To cancel the tun signal hights, push the switch in after st has re-turned to the center position Horn switch “ber” Press this switch to sound the horn Engine stop switch “O/" Set this switch to °(" before staring the engine Set this switch to “yy” to stop the engine in case of an emergen- cy, such as when the vehicle overturns or when the throttle cable is stuck. Start switch “@)” Push this switch to crank the engine with the starter icautiong See page 5-1 for starting instruc: tions prior to starting the engine. Hazard switch “8,” \With the key in the “ON" or *Pé" post: tion, use this switch to turn on the haz- ard light (simultaneous flashing of all tum signal lights) ‘The hazard light 1s used in case of an emergency or to warn other drivers when your vehicle is stopped where it INSTRUMENT AND CONTROL FUNCTIONS might be a trafic hazaré fe Guster CAUTION: ) Do not use the hazard light for an ex- aw ‘ester tended length of time, otherwise the / co battery may discharge. + Chuteh fever The clutch lever 13 located at the left handlebar gnp To disengage the clutch, pull the lever toward the handle- bar gnip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the igni- tion circu cutoff system (See page 3-18 ) 39INSTRUMENT AND CONTROL FUNCTIONS Shift pedal 4 Shit pedal The shift pedal ts located on the left side of the engine and ts used in com- bination with the clutch lever when shifting the gears of the 6-speed con: stant-mesh transmission equipped on this motorcycle. dial is aligned with the", * mark on the Brake lever brake lever ‘The brake lever is located at the nght handlebar gnp. To apply the front brake, pull the lover toward the handle. bar anp. Hite LA 4 a aye 1 Brake lover 2 Brake lover poston adwsting dial 9 7A" mark 4 Distance botwoen brake lever and handle bar gnp ‘The brake lever is equipped with a po- sition adjusting dial To adjust the ais- tanoe between the brake lever and the handlebar grip, tum the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate seiting on the adjusting 310Brake pedal 1 Brake pedal ‘The brake pedal is on the right side of the motorcycle To apply the rear brake, press down on the brake pedal INSTRUMENT AND CONTROL FUNCTIONS Fuel tank cap 1 Fue! tank cap lack cover 2 Unlock To open the fuel tank cap Open the fuel tank cap lock cover, in- sert the key into the lock, and then turn it 1/8 turn clockwise. The lock will be re~ leased and the fuel tank cap can be opened. To close the fuel tank cap +, Push the fuel tank cap into position ‘with the key inserted in the lock 2. Turn the key counterclockwise to the onginal position, removeeit, and then close the lock cover NOTE: ______ ‘The fuel tank cap cannot be closed un- sat tess the key is 1n the look in addition, the key cannot be removed tthe cap is ‘not properly closed and locked eee Make sure that the fuel tank cap is properly closed before ridiINSTRUMENT AND CONTROL FUNCTIONS Fuel io el a Oa 1 Fuel tank file tube 2 Fuet level Make sure that there 1s sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown '® Donot overfill the fuel tank, oth- erwise it may overflow when the fuel warms up and expands. © Avoid spilling fuel on the hot en- gi CAUTION: Immediately wipe off spilled fuel with a ciean, dry, soft cloth, since fuel may deteriorate painted surfac- 8 or plastic part ‘Recommended fuel UNLEADED GASOLINE ‘ONLY Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount 3.5L (0 92 US gal) (0.77 Imp gal) CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a research octane number of 91 or higher If knocking (or pinging} oc- curs, use a gasoline of a different brand or premium unleaded fuel Use of un- 32 leaded fuel wil extend spark plug ife and reduce maintenance costsINSTRUMENT AND CONTROL FUNCTIONS Catalytic converter This vehicle is equipped wth a catalytic converter in the muffler. _asBssSuasssnaania ‘The exhaust system is hot after op- eration. Make sure that the exhaust system has cooled down before do- ing any maintenance work. CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. ‘@ Use only unleaded gasoline. ‘The use of leaded gasoline will cause unrepairable damage to the catalytic converter. ‘© Never park the vehicle near pos- sible fire hazards such as grass ‘or other materials that easily burn. © Do not allow the engine to idle too long. Seat To remove the seat Ingett the key into the seat lock, turn it counterclockwise, and then pull the seat off 1 Seat lock 2 Unlock To install the seat insert the projections on the front of the seat into the seat holder, push the rear of the seat down to lock it in place, and then remove the key 343 1 Projection 2 Seat holder NOTE: PEELE Make sure that the seat is properly se- cured before nding,INSTRUMENT AND CONTROL FUNCTIONS ‘Storage compartment 1 Sap The storage compartment 1s located under the seat (See page 3-13 ) ae Do not exceed the maximum load of 203 kg (448 Ib) for the vehicle. When storing the owners manual or other documents in the storage com- Partment, be sure to wrap them in a plastic bag so that they will not get wet ‘When washing the vehicle, be careful not to let any water enter the storage compartment Adjusting the front fork This front fork 1s equipped with spring preload adwusting bolts and damping force adjusting screws FSI Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result. Spring preload 1 Sprng preload aqusting bok To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each fork leg in dt rection (a) To decrease the spring pre- load and thereby soften the 314 suspension, turn the adjusting bolt on teach fork leg in direction (b) + Standard soting 2 Curent cating 8 Front forceap bot NOTE: ‘Align the appropriate groove on the ad- justing mechanism with the top of the front fork cap bol. Spring preload setting: Minimum (soft) 8 Standard 7 Maximum (hard) 1INSTRUMENT AND CONTROL FUNCTIONS Damping force sett Hee cance ore Adjusting the shock absorber Make sure that the adjusting screw is. @ssembly turned to one of the four settings. This shock absorber assembly 1s equipped with a spring preload adjust 1 Damping forea adjusting sore 1 Turn the adjusting screw on each fork leg in direction (a) until the screw moves almost a 1/2 tum without clicking 2 Continue turing the adjusting screw in direction (a) until it licks This 1s the minimum setting 3 To increase the damping force, continue turning the adjusting screw in direction (a). The third click after the minimum setting 1S the maximum setting. I the adust- Ing screw is tured further in direc- tion (a), it will move half a turn before returning to the minimum Damping setting: ing ring and rebound and compression Minimum (sot | damping free aqustng knobs. t : 7 Standard foautiong 2 Never attempt to turn an adjusting Maximum (harg): mechanism beyond the maximum or 4 minimum settings. Spring preload 1 Spring preload adjusting ng 2 Spec wrench 8 Positon indicator To increase the spnng preload and thereby harden the suspension, turnINSTRUMENT AND CONTROL FUNCTIONS the adjusting nng in direction (a) To de- crease the spring preload and thereby soften the suspension, turn the adjust- Ing ring in direction (b. (@). To decrease the rebound damping force and thereby sotten the rebound damping, tum the adjusting knob in dt rection (b) ‘Spring preload setting: Minimum (soft 1 Standard 5 Maximum (hard) 9 Rebound damping force 1 Rebound damping force adjusting knob To increase the rebound damping force and thereby harden the rebound damp- Ing, turn the adwusting knob in direction Rebound damping setting: Minimum (soft). 20 clicks in direction (b)* Standard: 12 clicks in direction (b)* ‘Maximum (hard): 3 clicks in directon (b)* “With the adjusting knob fully turned in direction (a) 1 Compression damping fore adjusting ooo To increase the compression damping 346 force and thereby harden the compres- sion damping, turn the adjusting knob in direction (a) To decrease the com- pression damping force and thereby soften the compression damping, turn the adjusting knob in direction (b). Compression damping setting: Minimum (soft): 12 chicks in direction ()* Standard 11 clicks in direction (b)* Maximum (hard): 1 click in direction (b)* “with the adjusting knob fully turned in direction (a) NOT: eee eee ‘Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec- tfications due to smali differences in production, the actual number of clicks always represents the entire adustng range To obtain a precise adjustment, tt would be advisable to check the num ber of clicks of each damping force ad- justing mechanism and to modify theINSTRUMENT AND CONTROL FUNCTIONS speotfications as necessary EXNIIS _ This shock absorber contains highly pressurized nitrogen gas. For prop- er handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held re- sponsible for property damage or personal injury that may result from improper handling. ‘© Donot tamper with or attempt to ‘open the gas cylinder. © Do not subject the shock ab- sorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. © Do not deform or damage the gas cylinder in any way, as this will result in poor damping per- formance. ‘© Always have a Yamaha dealer service the shock absorber. Luggage strap holders 1 Luggage strap holder ‘There are four luggage strap holders ‘below the passenger seat, two of which can be tumed out for easier access ear Sidestand ‘The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot wile holeing the vehicle upright NOTE: EERE The builtin sidestand switch 1s part of the ignition circu cut-off system, which ‘cuts the igniton in certain situations. (See further down for an explanation of ‘the ignition circutt cut-off system } ee The vehicle must not be ridden with the sidestand down, or if the side- stand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting ina possible loss of control. Yama- ha’s ignition circuit cut of raising the sidestand before start- ing off. Therefore, check this systemINSTRUMENT AND CONTROL FUNCTIONS regularly as described below and have a Yamaha dealer repair it if it does not function properly. ignition circuit cut-off system ‘The ignition crrcult cutoff system (com- prising the sidestand switch, clutch ‘switch and neutral switch) has the fol lowing functions. © itprevents starting when the trans- mmission is in gear and the side- stand is up, but the clutch lever is not pulled. © Itprevents starting when the trans- mission's in gear and the clutch le- vor is pulled, but the sidestand 1s stil down © Itcuts the running engine when the transmission 1s in gear and the sid- estand is moved down Penodically check the operation of the igntion circutt cut-of system according to the following procedure if a malfunction is noted, have a ‘Yamaha dealer check the system be- fore riding. 38INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is turned on, 3 Tum the key on 4 Shit the transmission into the neutral position '5 Push the start switch Does the engine start? ]ves no | —___.} With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall? YES no -__________. Aor the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start? Yes no The system is OK The motorcycle can be ridden. per} NOTE eee This check 1s most reliable if performed with a warmed-up engine. The neutral swttch may be defective ‘The motoreycle should not be ridden until checked by a Yamana dealer Tho sidestand switch may be defective The motoreycle should not be ridden unt checked by a Yamatia dealer The cluten svntch may be defective ‘The motorcycle should not be ridden until cchcked by a Yamaha dealerPRE-OPERATION CHECKS ‘The condition of a vehicle is the owner's responsibilty Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements) Any damage, flu leakage or loss, of ite aur pressure could have serious consequences. Therefore, tis very important, n addition to a thorough visual mspec- tion, to check the following points before each ride NOTE: re-operation checks should be made each time the vehicie is used Such an inspection can be accomplished in a very short ‘ume; and the added safety it assures is more than worth the time involved. POEMS Hfany item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4PRE-OPERATION CHECKS Pre-operation check list ent ‘CHECKS PAGE Fuet ‘= Ghask toTiove Ral tank 1 Rotel # nscossary + Chock fuel ne for leakage 32, Engine oll Check of level in engine a Hi necessary, add recommended oilto spectied level Check vohcl fr all leakage 67 Coolant Chesk codlart level n reson Beet It necessary, add recommended coolant to spectiedlovol Check cookng sysiom for leakage 510 Front brake Check operation It soft or spongy, have Yamaha dealer bleed hydraulc systom CCheok brake pads for wear place f nocossery (Chock tld level n reservorr if necessary, add recommended rake flud o epectted level (Check hydraule systom for leakage 622 Roar brake ‘Check operation If soft or spongy. have Yarnaha dealer bod hydraule system Check brake pads for waar place if necassary Cheek tui level m coservowr I necessary, add reeommonded brake fund to spected level Check hyeraulc system for leakage 621,622 Ciuteh ‘Check operation LLubneate cable necessary Chock lever ree play Adjust t necessary 620 42PRE-OPERATION CHECKS read CHECKS PAGE 7 Wala are at operation BGO 5 + Check cate tee pay ee | © Ifnecessary, have Yamaha dealer adjust cable free play and lubncate cable. 616,625 and gp housing # a ce sre Tat opsratan i ROOT bunmimeninnd + Lubnate necessary ae + Chock chain tack eee 1 Aduet necessary = «Check chain condition a, 1 Leat i necessary + Chock or damage - {Check tre condion and read depth Wheels an tres co oe 616.619 LGomecti necessary TF Wake sure at poration is roo ae eee + Lubreate pedal protng pomts f necescary 926 eaaees + iake su tat operaton is smooth ; ee + Lubreato lover poling ports ovessary baa ae {Wako aoe tat operon is soo sere + Lubricate prvot it necessary fy Hake sre tat al nt, DORs and Seis re propa WaTES = eoatees ean |__« Tighten if necessary Tatra, igh, Sigrale | + Check operation = and switches ¢conectifnecoscary {Gh peraton of pnON CHEE GOTT SSE eee « Itsystem is defective, have Yamaha dealer check vehicle aoe 43POCNIS @ Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ‘© Never start the engine or oper- ate it in a closed area for any length of time, Exhaust fumes are poisonous, and inhaling them can cause loss of con- sciousness and death within a short time. Always make sure that there is adequate ventila- tion. © Before starting out, make sure that the sidestand is up. If the sidestand is not raised com- pletely, it could contact the ground and distract the opera- tor, resulting in a possible loss of control, OPERATION AND IMPORTANT RIDING POINTS Starting the engine In order for the ignition crrcutt cutoff system to enable starting, one of the following conditions must be met @ The transmission ts in the neutral position. @ The transmission is in gear with the clutch lever pulled and the sid- estand up. peters © Before starting the engine, check the function of the igni- tion circuit cut-off system ac- cording to the procedure described on page 3-18. @ Never ride with the sidestand down, 1 Turn the key to “ON” and make sure that the engine stop switch is setto"O" “Churion: The oll level warning light and en- gine trouble warning light should ‘come on for a few seconds, then go 54 off, If warning light does not go off, ‘see page 3-3 for the corresponding warning light circuit check. 2 Shift the transmission into the neu- tral positon. NOTE eee When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yama- hha dealer check the electrical circutt 3 Start the engine by pushing the start switch NoTe: If the engine fails to start, release the start switch, watt a few seconds, and then try again Each starting attemot should be as short as possible to pro- serve the battery Do not crank the en- gine more than 10 seconds on any one attempt icaurio For maximum engine life, always warm the engine up before starting off. Never accelerate hard when theOPERATION AND IMPORTANT RIDING POINTS is col vere engine is cold! Shitting Nore ae The engine is warm when it quickly re- sponds to the throttle. + Shit pedal 2 Neutral positon Shiftrg gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, ete The gear positions are shown in the il lustration (ir | HnBEnEnR RREEEEEEEEEREEEEEES To shift the transmission into the neu- tral posttion, press the shift pedal down repeatedly unt it reaches the end of ts travel, and then slightly raise it 52 Batic © Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long dis- tances. The transmission is Properly lubricated only when the engine is running. inade- quate lubrication may damage the transmission. © Always use the clutch while changing gears to avoid damag- ing the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.OPERATION AND IMPORTANT RIDING POINTS Tips for fuel consumption Fuel consumption depends largely on your nding style. Consider the following tips to reduce fuel consumption ‘© Shift up swifly, and avord high en- gine speeds duting acceleration @ Donot rev the engine while shifting down, and avoid high engne speeds with no load on the engine ‘© Turn the engine off instead of let- ting tide for an extended length of time (@g., in traffic jams, at trafic lights or at raload crossings). reducing Engine break-in ‘There is never a more important period in the ie of your engine than the penod between 0 and 1600 km (1000 mi). For this reason, you should read the follow- ing material carefully Since the engine is brand new, do not put an excessive load on it for the frst 1600 km (1000 mi) The various partsin the engine wear and polish themselves to the correct operating clearances During this period, prolonged ful-throt- tle operation or any condition that might result in engine overheating must be avoided. ‘0-1000 km (0-600 mi) ‘Avoid prolonged operation above 4000 risrin 1000-1600 km (600-1000 mi) ‘Avoid prolonged operation above 6000 simi [cauTion;| After 1000 km (600 mi) of operation, the engine oil must be changed, and 53 the oil filter element replaced. 41600 km (1000 mi) and beyond The vehicle can now be operated nor- mally. [CAUTION © Keep the engine speed out of the tachometer red zone. © If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi ole.OPERATION AND IMPORTANT RIDING POINTS Parking When parking, stop the engine, and then remove the Key from the main ‘switch. @ Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them. @ Donotpark ona slope or on soft a ground, otherwise the vehicle payovetiin CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials. 54Safety's an obligation of the owner. P niodic inspection, adjustment and lubr- catton wall keep your vehicle 19 the safest and most efficient condition pos- sible The most important points of in- spection, adjustment, and lubrication are explained on the folowing pages The intervals given in the penodic maintenance and lubrication chart should be simply considered as a gen- feral guide under normal riding condi- tons However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHI- CAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER- VALS MAY NEED TO BE SHORT- ENED Avan if you are not familiar with mainte- nance work, have a Yamaha dealer do itfor you. PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit 1 Owner’ tol The owner's tool kits located inside the storage compartment under the seat (See page 3-13) The service information included in this manual and the tools provided in the owner's tool kt are intended to assist you in the performance of preventive maintenance and minor repairs. How: ‘ever, additonal tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE: —_____ if you do not have the tools or expert ence required for a particular job, have et a Yamaha dealer perform it for you. ENGI _ __ Modifications not approved by Yamaha may cause loss of perfor- mance and render the vehicle un- safe for use. Consult a Yamaha dealer before attempting any chang- es.PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance and lubrication chart NOTE: ‘© The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km @ Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical sials ‘ODOWETER READING ( 1000km) ANNUAL No. ew (CHECK OR MAINTENANCE JOB 1 [| 2% [ 3 | a0 | CHECK [+] [Fueling = Chek Toe ose for eradks or damage Wy v chest conan Y Y 2) Spark plugs Giean ara regap | Hl = Repace La z 5 + Check valve Goarance 3] [valves S Aast Every 40000 air fiereioment = Foplace z + Chosk operation " 5) [outer ahd vfvly]fyvly + Ghoak operation, Rad Tove and voice Tora] 8] Front brake age | 7 Replace brake pads | Whereis’ worn etm r = + Check operation, alan and voce TormaBER | Ty yy Pw 7|*|Roar broke age = Replace Ba BGS Wherarer worn heim = leuneed = Check or eracks or damage a a a PIE eee = Fopiace 5 Even Fyea8 3 hess + Check out ard To damage Dery pyPERIODIC MAINTENANCE AND MINOR REPAIR BOWETER HERDING 1000 NO. TEM CHECK OR MAINTENANCE JOB i _| ANNUAL 7 70 | 20 | 30 | 40 | CHECK 7 Se Tt a aT aS tla > Repo receeay eel yy © Check aur pressure 7 e + Sonera coos 7 at sags Sie be or ono oom Tht ean Git oprah a ie Da Tht 2)" |Sunner ‘> Lubricate wih hithium-soap-based grease Every 50000 km SE alS eeel Every 1000 km and after washing the motorcycle or 12), [rve chain {Mata core nat he esr nee propery aligned ¥ rater wes : Clean and lubricate "9 ra i: Geb aya Sg TT oa eee eer = Lubmeate with ihivi-soap-based grease 7” Every 20000 Fn i ‘> Make sure that all nuts, bolts and screws are properly eH 7 |= [enaon testers ‘aera 5 + oh epo maT | - i] | sesame 7 Bick vrviv |e ls = satan sen ——| ore opar Ta thy Thy werent or + Ghek Spa an BOTT a oon i EERO cnet operator and nek sor Fase viele ar aropensin in| > Chas a 1 |rm anc Gomocting a — rman conn + Lubrate mt aburoap oad gee | 5 Y Zi [Eosrons et sien | Ra ani gave a yRoRERBOT ——| “TV z | lengine oi ap ylvftvjyv]wly 1 Chek vlan ve foro aage a Tee oT or some |= Ross 7 cleciiaser Cra A A oS RE Ta | 24)" [Sooting syste + Change Every 3 years 63PERIODIC MAINTENANCE AND MINOR REPAIR ‘ODOMETER READING (1000) _| ANNUAL 1 w | 20 | a | 49 | CHECK No. ew CHECK OR MAINTENANCE JOB Front and rear brave es] = |Feomt ae «+ Check operation vivlvqy|- | [hiowng pari ana cables + Labacate z usmg [> Chek open Bra TES Fay a] [Piatto crip housing | est me tote cable fre plays necessary vtvfululdy ni «Lubricate the throttle gnp housing and cable + hacks area va, reed val, and ROSS TO 23} ai inaucton system samage vivfudugy Replace me entre aciecicion sytem tneoossary | | Make ai oaRaURT Be |—+Cscx he sre carp fr oosenass z Tay ]Ciehis, stanats and = Check operatan Foeeelcy 9)" switches + Adjust headight beam Y PE Mi ui Note: © Arfiter + This model's air fiter is equipped with a disposable ol-coated paper element, which must not be cleaned with com- pressed air to avoid damaging tt + The air fiter element noeds to be replaced more frequently when riding in unusually wet or dusty areas © Hydraulic brake service + Regularly check and, if necessary, correct the brake fluid level + Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid + Replace the brake hoses every four yeats and if cracked or damaged o4PERIODIC MAINTENANCE AND MINOR REPAIR Removing and _ installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance Jobs descnbed in this chapter. Refer to this section each time a cowing or panel needs to be 1e- moved and installed 4 Cowting 8 1 Screw 2 Panel 2 Quek fastener en NOTE: beimiuhgapener sien The quick fastener 1s removed by push- Atte theca he athe center pin in with a sorewdnver, Remove the cowling serews and the ang then pulling the fastener out ‘quick fastener, and then pull the cowl: ing off as shown 4 Cowing A v1 2 2 Panel oS 1 Quick fastener (attr removal) 2 Quick fastener (heloro instalation) 65PERIODIC MAINTENANCE AND MINOR REPAIR Tounstall the cowling Place the cowiing in the original pos!- tion, and then install the screws and the quick fastener NOTE: __ To install the quick fastener, push the center pin out so that it will protrude from the fastener head, insert the fas- tener into the cowling, and then push the protruding pin in unbl itis fush wath the fastener head Panels A and B Toremove als 1. Remove the corresponding cowl: ing A or B. (See page 6-5.) 2 Remove the seat page 3-13) 3, Remove the screw, and then take the panel off (See Tounstall the panel 1 Place the panel in the orginal po: ston, and then install the screw 2 Install the seat and the cowiing 1 Panel 6 66 Checking the spark plugs The spark plugs are important engine components, which should be checked perodically, preferably by a Yamaha dealer. Since heat and deposits wll cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic mainte- anes and lubrication chart In addition, the condition of the spark plugs can re- vveal the condition of the engine The porcelain msulator around the cen- ter elactrode of each spark plug should bea medium-to-ighttan (the ideal color when the vehicle 1s ridden normally), and all spark plugs installed in the en- gine should have the same color. f any spark plug shows a distinctly different ‘color, the engine could be defective. Do Not attempt to diagnose such problems yourself Instead, have a Yamaha deal- er check the vehicle Ifa spark plug shows signs of electrode erosion and excessive carbon or other deposts, it should be replacedPERIODIC MAINTENANCE AND MINOR REPAIR ‘Speartied spark plug NGK/DPR8EA-9 DENSO/X24EPR-U9 Before installing a spark plug, the spark plug gap should be measured with a ‘wire thickness gauge and, if necessary, adjusted to specification = =I 1 Spark plug gap Spark plug gap (0.8-0 9 mm (0.031-0.035 in) Clean the surface of the spark plug «gasket and its mating surface, and then ‘wipe off any grime from the spark plug threads. Tightening torque: Spark plug 17.5 Nm (1 75 avkaf, 127 fbf) NOTE: Ita torque wrench is not available when installing @ spark plug, a Good estimate of the comect torque is 1/4-1/2 turn past finger tight. However, the spark plug should be tightened to the speci- fied torque as soon as possible 7 Engine oil and filter element ‘The engine oil level should be checked before each ride. in addition, the o must be changed and the ol iter ele- ment replaced at the intervals spectied 1m the periodic maintenance and lubs- cation chart To check the engine oil level 1. Place the vehicle on a level sur- face and hold ttn an upright post tion NOTE: __ ot Make sure that the vehicle s positioned straight up when checking the ol! level JA slight tito the side can result in a false reading 2 Start the engine, warm up for 15 ‘minutes, and then turn it off 3 Warta few minutes unti the oil set tles, remove the all filer cap, wipe the dipstick clean, insert it back into the of filer hole (without sorewing ttn and with the arrow matk pointing upward as shown),PERIODIC MAINTENANCE AND MINOR REPAIR and then remove it again to check the oil level, NOTE: The engine oil should be between the minimum and maximum level marks. ol 1 Engine ol er cap + Engng al tiles cap 2 Disk 3 Maximum leval mack 4 Mieumum lvel mark ‘CAUTION: Do not operate the vehicle until you know that the engine oil level is suf- ficient, | da WARNING Boe Never remove the engine oil tank cap after high-speed operation, oth- erwise hot engine oil could spout out and cause damage or injury. Al- ways let the engine oil cool down sufficiently before removing the oil 68 tank cap. 4 Ifthe engine oils below the min mum level mark, add sufficient oll of the recommended type to raise itto the correct level. 5 Install the ofl fiter cap. Wore Eee ert ‘@ The engine oil tank is located be- hind the cylinders © The engine oll should be between the minimum and maximum level marks To change the engine oil (with or without oil filter element replace- ment) 1. Stan the engine, warm it up for several minutes, and then turn it off 2, Place an oil pan under the engine to collect the used oil 3 Remove the engine oll filer cap and drain bolts to drain the oil from the crankcasePERIODIC MAINTENANCE AND MINOR REPAIR 1 Engine a ean bot A NOTE: ‘Skip steps 4-6 if the oll filter element is not being replaced 4 Remove the al fiter element cover by removing the bolts 1 Engne ol drain bolt 8 2 Oiltiter element cover 3 Bot 5 Remove and replace the all fiter element and O-angs, installing the bolts, then tightening them to the specttied torque. Tightening torque: Oil fiter element cover bolt 10.Nm (10 m-kgf, 7.2 ttIb!) NOTE: Sasseeaeseeennase Make sure that the O-rings are properly seated 7 Install the engine oil drain bolts, and then tighten them to the spec- ified torques. Tightening torques: Engine oll drain bott A 35 Nm (8.5 mkgf, 25 fbf) Engine oil drain bolt B: 35 Nm (3 5 m-kgf, 25 frlbf) 1 Oltiter element 2 Ong 6 Install the all fer element cover by 69 8 Add the specified amount of the recommended engine oil, and then install and tighten the oi filer capPERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oll ‘See page 8-1 Oil quanti Without ol fiter element replace- ment 3.80 L (4.02 US qt) (334 Imp a) ‘With oil fiter element repiace- ment 9901 (4.12 US at} (3.43 Imp.qt) -AUTION: @ In order to prevent clutch slip- page (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do ls with a diesel spec ofa not use fication of “CD” or er quality than sper addition, do not use oils labeled “ENERGY CONSERVING II” or higher. ‘® Make sure that no foreign mate- rial enters the crankcase. 9 Star the engine, and then letit idle ‘for several minutes while checking itfor ol leakage. Ifoilis leaking, m- mediately turn the engine off and check for the cause 10 Tum the engne off, and then check the oil level and correct it if necessary 10 Coolant The coolant level should be checked before each nde In addition, the cool- ant must be changed at the intervals spectted in the periodic mantenance and lubrication chart To check the coolant level 1 Place the vehicle on the center- stand NO Tes eee eee eee ‘© The coolant level must be checked ‘on a cold engine since the level vanes with engine temperature, © Make sure that the vehicle 1s post ‘toned stravght up when checking the coolant level A slight tit to the side can result in a false reading. 2 Check the coolant ievel in the cool- ant reservoir NOTE: The coolant should be between the minimum and maximum level marksPERIODIC MAINTENANCE AND MINOR REPAIR 1 Cosiant reservar 2 Maximum level mark Minium vel mark 3 If the coolant 1s at or below the minimum level mark, remove pan- el B (See page 6-5), remove the reservoir cap, add coolant to the maximum level mark, and then in- stall the reservoir cap and the pan- al 1 Coolant reservar cap Coolant reservorr capacty (up to the maximum level mark) 0.25 L (026 US qt) (022 Imp at) [CAUTION © If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. ‘© If water has been used instead of coolant, replace it with cool ant as soon as possible, other- wise the engine may not be sufficiently cooled and the cool- eat ing system will not be protected against frost and corrosion. © If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. PON Never attempt to remove the radiator cap when the engine is hot. NOTE: tebe eee EHee-EEEee EEE © The radiator fan is automatically switched on or off according to the coolant temperature in the radia- tor @ If the engine overheats, see page 6-39 for further instructions To change the coolant 1 Place the vehicle on a level sur- face and let the engine cool it nec- essary 2, Remove page 3-13) the seat. (SeePERIODIC MAINTENANCE AND MINOR REPAIR 3, Remove cowing B and panel B. {See page 6-5) 4, Remove the fuel tank bolts, and then iit the fuel tank to position it away from the coolant reservoir (Do not disconnect the fuel hoses’) 5 Place a container under the engine to collect the used coolant. 6. Remove the radiator cap retaining bolt and the radiator cap PII Never attempt to remove the radiator cap when the engine is hot, 1 Radator cap retaining bolt 2 Radiator cap 7 Remove the coolant drain bolts to drain the cooling system 1 Coolant eran Bott 8 Remove the coolant reservorr bolt the coolant reservoir by opening the cap, then turing the reservoir upside down 11. Install the coolant reservor by placing it in the original position, ‘then instaling the bolt 12 Alter the coolant 1s completely ‘rained, thoroughly flush the cool- ing system with clean tap water. 19 Install the coolant drain bots, and then tighten them to the spectied torque. NOTE: ‘Check the washers for damage and re- place them it necessary 1 Bol 2 Coolant reservore 9 Pull the coolant reservoir upward and away from the vehicle 10 Drain the remaining coolant from en Tightening torque: Cooiant drain bolt: 10Nm (1 0 mkaf, 7 2 ftlof) 14 Pour the recommended coolant into the radiator until it 1s fullPERIODIC MAINTENANCE AND MINOR REPAIR ‘Antifteezelwater moxture rato. 11 Recommended antifreeze High-quality ethylene glycol antireeze containing corro- sion inhibitors for aluminum engines Coolant quantity: Radiator capactty (including all routes) 1.70 L (1 80 US qt) (3.50 Imp at) Coolant reservorr capacity. 025 | (0 26 US qt) (0 22 Imp qt) [caution? ‘@ If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. © if water has been used instead of coolant, replace it with cool ant as soon as possible, other- wise the engine may not be sufficiently cooled and the cook ing system will not be protected against frost and corrosion. © if water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. 16 Install the radiator cap, start the engine, let tt idle for several min- utes, and then tur it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary, add sutficient coolant tnt it reaches the top of the radia~ tor, and then install the radiator cap and the cap retaining bolt 17 Check the coolant level in the res. ervoir If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap 1, Install the fue! tank '@ Before installing the fuel tank, make sure that the fuel hoses are not damaged. if any fuel hose Is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- wise fuel may leak, ‘© Make sure that the fuel hoses are properly connected and routed, and not pinched. ‘© Be sure to place the fuel tank breather hose in the original po- ion, 4 Install the panel, the cowling, and the seat 20 Start the engine, and then check the vehicle for coolant leakage It coolant is leaking, have a Yamaha dealer check the cooling system.PERIODIC MAINTENANCE AND MINOR REPAIR Replacing the air filter element The air filter element should be re- placed at the intervals specified in the eniocic maintenance and lubrication ‘chart. Replace the air filter element more frequently if you are riding in un- usually wet or dusty areas. 1 Remove the seat (See page 3-13.) 2. Remove cowlings A and B as well as panels A and B. (See page 6-5) 3 Remove the fuel tank bolts, and ‘then lift the fuel tank away from the air fiter case. 4, Remove the air filter case cover by removing the screws. 4 Artiter case cover 2 Seren 5. Pull the air filter element out. 1 Arter element 6 Insert @ new air filter element into ry the air fiter case. Ieaurionj © Make sure that the air filter ele- ment is properly seated in the air filter case. ‘© The engine should never be op- erated without the air filter ele- ment installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn, 7 Install the ar fiter case cover by in- stalling the screws 8. Place the fuel tank in the onginal position and install the bolts. @ Before installing the fuel tank, make sure that the fuel hoses. are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- se fuel may leak. > sta ine ta ms Rl ee are properly connected andPERIODIC MAINTENANCE AND MINOR REPAIR routed, and not pinched. © Be sure to place the fuel tank breather hose and the fuel tank ‘overflow hose in the original po- sition. 9 Install the panels and cowlings 10 Install the seat Adjusting the engine idling speed The engine iding speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE:, The engine 1s warm when it quickly re- sponds to the throttle Check the engine iding speed and, i necessary, adjust it to specication by turing the throttle stop sorew. To in- crease the engine idling speed, turn the screw in direction (a) To decrease the engine idling speed, turn the screw in direction (b) e5, + Throttle stop sexe Engine iding speed 4100-1200 r/min NOTE: if the speciied iding speed cannot be obianed as descnbed above, have a ‘Yamaha dealer make the adjustmentPERIODIC MAINTENANCE AND MINOR REPAIR Adjusting the throttle cable Adjusting the valve clearance Tires free play ==) 1 Throttle cable foe play The throttle cable tree play should mea: sure 3.0-5.0 mm (0 12-0.20 in) at the throttle grip Periodically check the throttle cable free play and, if neces- ‘sary, have a Yamaha dealer adjust it The valve clearance changes with use, resulting in improper arr-fuel mixture andjor engine noise. To prevent this from occurring, the valve clearance must be achusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 616 To maumize the performance, durabil- ity, and safe operation of your motoroy- cle, note the following points regarding the speotfied tres. Tire air pressure The tire air pressure should be checked and, ifnecessary, adjusted before each ride PGI air pressure must be checked and adjusted on cold of the tires equals the ambient temperature). © The tire air pressure must be ad- justed in accordance with the riding speed and with the total weight of rider, passenger, car- go, and accessories approved for this model.Tire air pressure (measured on! cold tires): (0-90 kg (0-198 Ib) : Front 225 kPa (33 psi) (2 25 kgf/cm”) Rear 250 kPa (36 psi) (2 50 kal/em?) {90-203 kg (198-848 Ib) : Front 225 kPa (33 pst) (2 25 kgt/cm?) Rear. 290 kPa (42 psi) (2.90 kgticm?) High-speed riding: Front 225 kPa (33 ps!) (2.25 kat/em?) Rear 250 kPa (36 psi) (2.50 kgticm®) Maximum load 203 kg (448 Ib) “Total weight of rider, passenger, ‘cago and accessories ee Because loading has an enormous impact on the handling, braking, performance and safety characteris- ties of your motorcycle, you should PERIODIC MAINTENANCE AND MINOR REPAIR keep the following precautions in mind. @ NEVER OVERLOAD THE MO- TORCYCLE! Operation of an overloaded motorcycle may re- sult damage, loss of con- trol, or severe injury. Make sure that the total weight of rider, passenger, cargo, and accesso- ries does not exceed the speci- fied maximum toad for the vehicle. © Do not carry along loosely packed items, which can shift during a ride. © Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides. © Adjust the suspension and tire air pressure with regard to the load. ‘© Check the tire condition and air pressure before each ride. ear Tire inspes 12 . 1 Tue tread dooth 2 Tre sdewall 2 Tira wear necator The tres must he checked before each nde If the tre shows crosswise lines {minimum tread depth), ifthe tre has a nail or glass fragments i it, or if the sidewall 18 cracked, have a Yamaha dealer replace the tre immediately Minimum tre tread depth (front and rear) 4.0 mm (0.04 in) Nore: The tre tread depth limits may difer from country to country Always complyPERIODIC MAINTENANCE AND MINOR REPAIR with the local regulations caps are securely installed to SEH EEE alt prevent air pressure leakage. 7 2 3 B © Uso only the tire valves and ‘© Have a Yamaha dealer replace valve cores listed below to ‘excessively worn tires. Besides: avoid tire deflation during a ride. being illegal, operating the vehi- cle with excessively worn tires decreases riding stability and can lead to loss of control. © The replacement of all wheel and brake related parts, includ- je arvave ing the tires, should be left toa 3 113 arvae cap wih seal prareee cealete etre has ie This motorcycle is equipped with cast necessary professional knowl- wheal y i qUIppe thvah Reema eels and tubeless tres with valves '@ The front and rear tires should be of the same make and de- sign, otherwise the handling characteristics of the motorcy- cle cannot be guaranteed. © After extensive tests, only the tires listed below have been ap- proved for this model by Yama- ha Motor Co., Ltd. © Always make sure that the valve eePERIODIC MAINTENANCE AND MINOR REPAIR Front tire: Size 120/70 ZR18MIC (58W) ‘Manufacturerimodel METZELER/MEZ4 FRONT DUNLOP/D220FSTJ Tire air valve TRAIZ Valve core. #90004 (original) Rear tire: Size 160/60 ZR17MIC (69) Manutacturerimodel METZELER/MEZ4 DUNLOP/D220STJ Tre air valve TRAI2 Valve core #9000A (onginal) FN i This motorcycle is fitted with su- ertineancopronemiiant lowing points in order to make the most efficient use of these tires. ‘@ Use only the specified replace- ment tires. Other tires may run the danger of bursting at super high speeds. © Brand-new tires can havea rela- tively poor grip on certain road surfaces until they have been “broken in”. Therefore, it is ad- visable before doing any high-speed riding to ride con- servatively for approximately 100 km (60 mi) after installing a new tire. © The tires must be warmed up before a high-speed run. © Always adjust the tire air pres- sure according to the operating conditions 19 Cast wheels To maximize the performance, durabit tty, and safe operation of your vehicle, note the following points regarding the specrtied wheels. @ The whee! ims should be checked for cracks, bends or warpage be: fore each ride. If any damage 1s found, have a Yamaha dealer re- place the wheel Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced © The wheel should be balanced whenever etther the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance, adverse han- dling characteristics, and a short- ened tre life @ Ride at moderate speeds atter changing a tire since the tre sur- face must itst be “broken in” for t to develop tts optimal characteris- tes.PERIODIC MAINTENANCE AND MINOR REPAIR Adjusting the clutch lever free play 4 Lockrot (elute lever) 2 Clutch lever fee play agus bolt 3 Clutch over tee play The clutch lever free play should mea- sure 10.0-15 0 mm (0.39-0 59 in) as shown, Periodically check the clutch le- ver free play and, necessary, adjust i as follows. 1. Loosen the focknut at the clutch le- ver 2. To inctease the clutch lever free Play, turn the adjusting bolt in di- rection (a) To decrease the clutch lever free play, turn the adjusting bolt in direction (b) 3.1f the specified clutch lever tree play could be obtained as de- scribed above, tighten the locknut, and skip the rest of the procedure, otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction (a) to loos- en the clutch cable 8. Loosen the locknut at the crank- 1 Locknut (crankcase) 2 Clutch lever ree play adjusting nut (erank case) 6 To increase the clutch lever free play, tur the adjusting nutin direc tion (a} To decrease the clutch le- ver free play, turn the adjusting nut ozo in direction (b). 7. Tighten the locknut at the clutch le- ver and the crankcasePERIODIC MAINTENANCE AND MINOR REPAIR Adjusting the brake pedal position 1 Dstance bemoan brake pedal ad footrest The top of the brake pedal should be positioned approximately 32.0 mm (1.26 1in) below the top of the footrest as shown. Periodically check the brake pedal postion and, necessary, have a Yamaha dealer adjust it A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydrat system, have a Yamaha dealer bleed the system be- fore operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an acci- dent. 621 Adjusting the rear brake light switch 1 Rear brake ight atch 2. Rear brake light sertch adjusting nut The rear brake light swntch, which is ac- tivated by the brake pedal, 1s properly adjusted when the brake light comes on yust before braking takes effect It necessary, adjust the brake light switch as follows, Tum the adjusting nut while holding the tear brake light switch im place To make the brake light come on earler, turn the adjusting nut m direction (a) To make the brake light come on later, turn the adjusting nut in direction (b.PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads ‘The front and rear brake pads must be checked for wear at the intervals spec: ted in the penodic maintenance and lubneaton chart. Front brake pads 1 Brake pad wear ndicator groove Each front brake pad 1s provided wath a wear indicator groove, which allows you to check the brake pad wear with- ‘out having to disassemble the brake To check the brake pad wear, check the wear indicator groove If a brake pad has worn to the point that the wear Indicator groove has almost disap- peared, have a Yamaha dealer replace the brake pads as a set. Rear brake pads 1 Uning thickness ‘Check each rear brake pad for damage and measure the lining thickness Ifa brake pad 1s damaged or if the lining ‘thickness is less than 0.8 mm (0 03 n), have a Yamaha dealer replace the brake pads as a set 622 Checking the brake fluid level Front brake Rear brake 1 Mkrsmum level mark Insufficient brake fluid may allow air to enter the brake system, possibly caus- Ing it to become ineffectiveBefore riding, check that the brake fluid 1s above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads andior brake system leakage If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: @ When checking the fluid level, make sure that the top of the brake ‘uid reservorr is level © Use only the recommended quality brake fluid, otherwse the rubber seals may deteriorate, causing leakage and poor braking perfor mance. Recommended brake fluid DOT 4 © Reiil wth the same type of brake fluid Mang fluids may result in a harmful chemical reaction and lead to poor braking performance © Be careful that water does not en- ter the brake fluid reservotr when PERIODIC MAINTENANCE AND MINOR REPAIR refiling Water will significantly lower the boting point of the turd ‘and may result in vapor lock © Brake fluid may deteriorate paint- ed surfaces or plastic parts. Al- ways clean up spied fluid immediately @ As the brake pads wear, its nor mal for the brake fluid level to grad- ually go down However, if the brake fluid level goes down sud- denly, have a Yamaha dealer check the cause 823 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervais specified in the NOTE after the penodic mannte- nance and lubrication chart In addition, have the oil seals of the master cylin- ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. © Cll seals Replace every wo years @ Brake hoses Replace every four yearsPERIODIC MAINTENANCE AND MINOR REPAIR Drive chain slack The drive chain slack should be checked before each ride and adjusted tnecessary. To check the drive chain slack 1 Place the motoreycle on a level surface and hold itn an upright po- sition NOTE: When checking and adjusting the drve chain slack, the motoreycle should be Positioned straight up and there should bbe no weight on it 2 Shift the transmission into the neu tral position. 3 Move the rear wheel by pushing the motorcycle to locate the tight- est portion of the dive chain, and then measure the drive chain slack as shown Dive chain slack 50 0-60.0 mm (1 97~2 36 in} + Dive chan stack 4 Ifthe dnve chain slack 1s incorrect, adjust tt as follows To adjust the drive chain slack 1 Ade nut 2 Drive chain slack adjusting bot 3 Locknut 4 Aigament marks 624 1 Loosen the axle nut, the brake cal- 'per bracket bolt and the locknut on each side of the swingarm, 1 Bake caliper bracket bot 2 Brake cater bracket 2. To tighten the dive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loos: en the drive chain, tur the adjust- ing bolt on each side of the ‘swingarm in direction (b), and then push the rear wheel forward ome Ee Using the alignment marks on each side of the swingarm, make sure that both chain pullers are inthe same posi-tion for proper wheel alignment [caution? Improper drive chain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. - 3 Tighten the locknuts, and then tighten the axle nut and the brake caliper bracket bott to the specified torques Tightening torque: Axle nut 160 Nm (15.0 mgt, 108 5 trib’) Brake caliper bracket bolt 40 Nm (4 0 mrkgf, 29 fib) PERIODIC MAINTENANCE AND MINOR REPAIR Lubricating the drive chain The drive chain must be cleaned and lubnoated at the intervals specitied in the penodic maintenance and tubnca- tion chart, otherwise it will quickly wear out, especially when nding im dusty or wet areas Service the drive chan as follows Icaution} The drive chain must be lubricated after washing the motorcycle or riding in the ra 1 Clean the drive chain with kero- sene and a small soft brush IcauTionE To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2, Wipe the drive chain cry 3. Thoroughly lubricate the drve chain with a special O-ring chain lubricant 6.25 icaibrion# Do not use engine oil or any other lu- bricants for the drive chain, as they may contain substances that could damage the O-rings.PERIODIC MAINTENANCE AND MINOR REPAIR Checking and lubricating the cables The operation of all control cables and the conditten of the cables should be checked before each ride, and the ca- bles and cable ends should be lubncat- ed if necessary Il'a cable 1s damaged ‘or does not move smoothly, have a ‘Yamaha dealer check or replace it Recommended lubricant Engine of Damage to the outer sheath may in- terfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. Checking and lubricating the throttle grip and cable The operation of the throtle grip should be checked before each ride In addr tion, the cable should be lubncated or replaced at the intervals specified in the periodic maintenance chart. 626 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ‘ide, and the pedal pivots should be lu- bricated f necessary. Recommended lubricant Lithium-soap-based grease {all-purpose grease)Checking and lubricating the brake and clutch levers ‘The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu- bcated if necessary Recommended lubneant Lithium-soap-based grease {all-purpose grease} PERIODIC MAINTENANCE AND MINOR REPAIR Checking and lubricating the Lubricating the suspension sidestand “The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubneated if necessary eee ee ithe sidestand does not move up and down smoothly, have a Yamaha dealer check oF repair it. Recommended lubricant Lithium-soap-based grease (all-purpose grease) oar rear + Grease nipple The pwoiing pomts of the rear suspen- sion must be lubricated at the intervals specified in the periodic maintenance and iuoneation chart Recommended lubricant. Lithium-soap-based greasePERIODIC MAINTENANCE AND MINOR REPAIR Checking the front fork ‘The condition and operation ofthe front fork must be checked as follows at the intervals spetfied in the periodic main- tenance and lubrication chart To check the condition ‘Securely support the vehicle 60 that there is no danger of it falling over. ‘Check the inner tubes for scratches, damage and excessive oll leakage To check the operation 1. Place the vehicle on a level sur- face and hold it in an upright pos! tion 2 While applying the front brake, push down hard on the handiebars several times to check if the front fork compresses and rebounds smoothly fchidyoni? If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re- pair it. 626 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation Of the steering must be checked as fol- lows at the intervals specified in the pe- viodc maintenance and. lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground as ‘Securely support the vehicle so that there is no danger of it falling over. 2 Hold the lower ends of the front fork legs and try to move them for- ward and backward. if any free play can be felt, have a Yamaha dealer check or repair the steeringPERIODIC MAINTENANCE AND MINOR REPAIR Checking the wheel bearings ‘The front and rear wheel beannngs must be checked at the intervals specified in the periodic maintenance and lubrica- tion chart If there 1 play in the wheel hhub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings 620 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water icautiony Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery. UNUGS Electrolyte is poisonous and dangerous since it contains suk furic acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and al- ways shield your eyes when working near batteries. In case of contact, administer the fol- lowing FIRST AID. of water. + INTERNAL: Drink large quan- tities of water or milk and im-PERIODIC MAINTENANCE AND MINOR REPAIR mediately call a physician, + EYES: Flush with water for 15 minutes and seek prompt medical attention, © Batteries produce explosive hy- qrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and pro- vide sufficient ventilation when charging it in an enclosed space. © KEEP THIS AND ALL BATTER- IES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the bat- tery as soon as possible if it seams to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle 1s equipped with optional electrical accessories To store the battery 1 Ifthe vehicle will not be used for ‘more than one month, remove the battery, fully charge tt, and then place it in @ cool, dry place 2 Ifthe battery willbe stored for more than two months, check it at least ‘once a month and fully charge it necessary. 3. Fully charge the battery before in- stallation. 4, Atter insiallation, make sure that the battery leads are properly con- nected to the battery terminals. ication? @ Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. @ To charge a sealed-type (MF) battery, a special (constant-volt- ‘age) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charg- er, have a Yamaha dealer charge your battery. 630 Replacing the fuses 1 Backup fuse (for odometer and clock) 2 Radiator fan fuse 3 Tarn signal ight nd nazar tse 4 lgnton tase 5 Snag system fuse 8 Headight uso 7 Spare fuse 8 Becrone uel mecton fuse 9 Man tuse The main fuse and the fuse box, which contains the fuses for the individual cr- ‘cuits, are located under the seat. (See page 3-13) lia fuse ts blown, replace tt as follows 1 Turn the key to 'OFF" and turn off the electncal citcutt in question 2 Remove the biown fuse, and theninstall a new fuse of the specified amperage. Specified fuses: Main fuse 400A Headlight fuse 150A Radiator fan fuse 200A Ignition fuse” 100A ‘Signaling system fuse. 100A Backup fuse. 50A Electronic fuel injection fuse 100A ‘Turn signal lightand hazard fuse: 100A {caution Do not use a fuse of a higher amper- age rating than recommended to avoid causing extensive damage to the electrical system and possibly @ fire. PERIODIC MAINTENANCE AND MINOR REPAIR 3 Turn the key to “ON" and turn on the electneal circuit m question to check if the device operates. 4 if the fuse immediately blows again, have a Yamaha dealer check the electrical system. eat Replacing a headlight bulb This model is equipped with two quartz bulb headights. If a headlight bulb burs out, replace it as follows. 1. Disconnect the headlight coupler, and then remove the headlight bulb cover. 1 Headlight bulb hotder 2 Headlight coupler 2 Unhook the headlight bulb holder, and then remove the defective bulb.ME touch ti PERIODIC MAINTENANCE AND MINOR REPAIR A >) 1 Yi 4 Headight bub holder i Headlight bulbs get very hot. There- fore, keep flammable products away from a lit headlight bulb, and do not bulb until it has cooled down, 3, Place a new bulb into position, and then secure it with the bulb holder ICAUTION: Take care not to damage the follow- ing parts: © Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from cil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af- fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb usinga cloth moistened with al- cohol or thinner. Headlight lens + Do not affix any type of tinted film or stickers to the head- ight lens. + Donot use a headlight bulb of ‘a wattage higher than speci- fied. 1 Do not ouch the glass par of the auld 4 Install the bulb cover, and then connect the coupler ose 5 Have a Yamaha dealer adjust the headlight beam if necessary.PERIODIC MAINTENANCE AND MINOR REPAIR Replacing the tail/brake light bulb 1 Remove the seat (See page 3-13.) 2 Flemove the socket (together with the bulb) by tuning it counter- clockwise 4 Socket 3 Remove the defectve bulb by pushing itn and turning it counter- clockwise 4 Insert a new bulb into the socket, push it in, and then turn it clock wise unt it stops. 5 Install the socket (together with the bulb) by turing it clockwase 6 Install the seat. 633 Replacing a turn signal |i bulb 4. Remove the turn signal light lens by removing the screw 1 Screw 2 Tun signat ight ens 2 Remove the defectve bulb by pushing tin and turning it counter- clockwisePERIODIC MAINTENANCE AND MINOR REPAIR 1 Turn sna ight bub 3 Insert a new bulb into the socket, push it in, and then turn it clock- wise until t stops 4. Install the lens by installing the sorew, [caution:: Do not overtighten the screw, other- wise the lens may break. ‘Supporting the motorcycle ‘Since this model is not equipped with a centerstand, follow these precautions when femoving the front and rear wheel or performing other maintenance requiring the motoreycle to stand up- tight. Check that the motorcycle is in a stable and level position before staring any maintenance. A strong wooden box can be placed under the engine for added stabilty. To service the front wheel 1 Stabiize the rear of the motorcycle by using a motorcycle stand or, f an additional motorcycle stand is not available, by placing a jack un- der the frame in front of the rear wheel 2. Raise the ‘ont wheel off the ground by using 2 motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or, rf a motor- cycle stand is not avaiable, by placing a jack etther under each side of the 64 frame in front of the rear whee! or under each side of the swingarm.PERIODIC MAINTENANCE AND MINOR REPAIR Front wheel To remove the front wheel pee @ Itis advisable to have a Yamaha dealer service the wheel. © Securely support the motorcy- cle so that there is no danger of It falling over 1 Loosen the front wheel axle pinch bolt, then the brake caliper bolts 2. Loosen the wheel axle with a 19-mm hexagon wrench 1 Wheel axe 2 Front wheal axle pinch bot 3 Lift the front wheel off the ground according to the procedure on page 6-34 4 Remove the brake hose holders by removing the bolts, 5. Remove the brake calipers by re- moving the bolts 1 Brake hose holder 2 Bot 3 Brake caliper 6 Pull the wheel axle out, and then remove the wheat "CAUTION: Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut. 635 To install the front wheel 1 Lift the wheel up between the fork legs 2, Insert the wheel axle, 3. Lower the front wheel so that its cn the ground 4 Install the brake calipers by nstall- ing the bolts NOTE: Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders by installing the bots 6 Tighten the wheel axle, the wheel axle pinch bolt and the brake call- per bolts to the specified torques Tightening torques: Wheel axe 72.Nm (7.2 mkgf, 52 trot) Front wheel axle pinch bolt 20 Nm (2.0 mkgf, 14 5 ttt) Brake caliper bolt 40 Nm (4.0 mkof, 29 fribf)PERIODIC MAINTENANCE AND MINOR REPAIR 7. Push down hard on the handlebar use several times to check for proper Rear wheel fork operation To remove the rear wheel ia is advisable to have a Yamaha dealer service the wheel, © Securely support the motorcy- cle so that there is no danger of ittalling over. 1 Ade nut 2 itv chan stack acgsting bot 1. Remove the drive chain cover by 3 Lacknut removing the quick fasteners and 4 Algamont marks cg 2 Loosen the axle nut and the brake caliper bracket bott 1 Bott ck fastener baueias 1 Brake caper bracket bolt 2 Brake caliper bracket 636PERIODIC MAINTENANCE AND MINOR REPAIR 8 Lift the rear wheel off the ground according to the procedure on page 6:34 Remove the axle nut. Loosen the locknut on each side of the swnngarm. 6 Turn the drive chain slack adjust: ing bolts fully in direction (a) 7 Push the wheel forward, tighten the caliper bracket bolt, and then remove the drve chain from the as rear sprocket. NOTE: ‘The dave chain does not need to be disassembled in order to remove and instal the rear whee! 8 Pull the wheel axle out, and then remove the wheel CAUTIONS Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake caliper pistons will be forced out. To install the rear whee! 4. Install the wheel by nserfing the wheel axle from the night hand side NOTE: Make sure that there 1s enough space between the brake pads before install sng the whee! 2 Install the rive chain onto the rear sprocket 3. Loosen the brake caliper bracket bolt 4, Adjust the drive chain slack (See page 6:24) 5 Install the axle nut, and then lower the rear wheel so that it on the ‘ground a7 6 Tighten the axle nut and the brake caliper bracket bolt to the specttied torques. Tightening torques: Axle nut 450 Nm (15 0 mgt, 108 5 ft bf) Brake caliper bracket bolt 40 Nm (4 0 am-kaf, 29 0 ftlbf) 7 Install the drive chain cover by in- stalling the bolts and quick fasten- os 1 Quick fastener (after removal) 2 Quick fastener (betore instalation) NoTE: To install a quick fastener, push the pinPERIODIC MAINTENANCE AND MINOR REPAIR bback so that it will protrude from the fas- ‘tener head, and then insert the fastener and push the protruding pin in unt tis. ‘iush with the fastener head, Troubleshooting Although Yamaha motoreycles recerve a thorough inspection before shipment from the factory, trouble may occur dur- ing operation. Any problem in the fuel, ‘compression, or ignition systems, for example, can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your: selt However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expenence, and know-how to service the motorcycle properly. Use only genuine Yamaha replace- ment parts Imitation parts may look like ‘Yamaha parts, but they are often inter or, have a shorter service life and can lead to expensive repar bls 638PERIODIC MAINTENANCE AND MINOR REPAIR Troubleshooting charts Starting problems or poor engine performance PEIN Keep away open flames and do not smoke while checking or working on the fuel system. creck na compression Operate tn let star 2. Compression = ——————) +] meres enough ue ie renee Le sary tot “The one coe heck he cer ‘Chock thaaton 3. Ignition Remove ho spar plugs Tye Lo aa ac ana caneaie —|_ [ Opt ome aay anton Mei shptes Zinc satsbos J" [posocnesarmn 4. Battery for; fies aha ear neck hevehele | {Tee engoe does notsat Check he bony The aie us ove Lf rr tery 03 Tia eg i oe 639 Hevea Yamane dealerPERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating POON ‘@ 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. Be sure to wait until the engine has cooled. © After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap. maha dealer cheok Treee |, rave “pa colentavel slow ; eekage [Jang epathe cong sytem 7 There ‘Wat unt he (Checks colantioveln he aaa | = nescosam se NOTE) engines ccoted |] reservar ard rasator The otenever |_| Stan the engine W the engine overheats apam, haves a 80K "Yamaha dealer chock and ropa to ceerg aster NOTE: coolant is not available, tap water can be temporanly used instead, provided that itis changed to the recommended coolant as soon as possibleMOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the tech- nology, it also makes it more vulnera- ble Rust and corrosion can develop even if high-quality components are used A tusty exhaust pipe may go un- noticed on a car, however, it detracts from the overall appearance of a motor- cycle Frequent and proper care does not only comply with the terms of the ‘warranty, but t will also keep your mo- torcycle looking good, extend its life and optimize its performance. Before cleaning + Cover the mutter outlets with plas: tc bags after the engine has cooled down. 2 Make sure that ali caps and covers as well as all electrical couplers and connectors, inoluding the spark plug caps, are tightly in- stalled. 3. Remove extremely stubborn di, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod- ucts onto seals, gaskets, sprock- ets, the dive chain and wheel axles Always nse the dirt and de- greaser off with water Cleaning {CAUTIONS © Avoid using strong acidic whee! cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the af- fected area any longer than in- structed. Also, thoroughly rinse the area off with water, immedi- ately dry, and then apply acor- rosion protection spray. ‘© Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. © Do not use any harsh chemical products on plastic parts, Be sure to avoid using cloths or m sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust re~ movers or inhibitors, brake flu- id, antifreeze or electrolyte. Do not use high-pressure wash- ers or steam-jet cleaners since they cause water seepage and deterioration in the following ar- eas: seals (of wheel and swing- arm bearings, fork and brakes), electric components (couplers, connectors, instruments, ‘switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning com- pounds for plastic may leave scratches on the windshield. Test the product on a small hid- den part of the windshield to make sure that it does not leaveMOTORCYCLE CARE AND STORAGE any marks. If the windshield is scratched, use a quality plastic polishing compound after washin, After normal use Remove dirt with warm water, a mild detergent, and a sott, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas, Stubborn dirt and insects will come off more easily the area is covered with a wet cloth for a few minutes before cleaning, After nding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads ‘during winter are extremely corrosive in ‘combination with water, carry out the following steps atter each ride in the rain, near the sea or on salt-sprayed roads. Nove; Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa- ter and a mild detergent, after the engine has cooled down ‘cabmions Do not use warm water since it in- creases the corrosive action of the salt, 2 After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nick- elvlated, surfaces to prevent cor rosion, After cleaning 1 Dry the motorcycte with a chamors ‘or an absorbing cloth 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3 Use a chrome polish to shine chrome, aluminum and stain- less-steel parts, including the ex- haust system (Even the thermally Induced discoloing of stain: less-steel exhaust systems can be removed through polishing ) 4 To prevent corrosion, it $ recom- 72 mended to apply a corrosion pro- tection spray on all metal, including chrome- and nickel-plat- ed, surfaces. 5. Use spray ot! as a universal clean- er to remove any remaining dirt 6. Touch up minor paint damage caused by stones, etc 7 Wax all painted surfaces. 8 Let the motorcycle dry completely before storing or covening it Make sure that there is no oil or ‘wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or ac- etone, and wash the tires with sin gates weal ela ne gent. ‘@ Before operating the motorcy- cle test its braking performance Sid carnran pens[exérion? © Apply spray oll and wax spar- ingly and make sure to wipe off any excess. © Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. @ Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: ‘Consult a Yamaha dealer for advice on what products to use MOTORCYCLE CARE AND STORAGE ‘Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover ,CAUTION: ‘® Storing the motoroycle in a poorly ventilated room or cover- ing it with a tarp, while itis sti ‘wet, will allow water and humi ity to seep in and cause rust. © To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemi- cals ate stored. Long-term Before storing your motorcycle for sev- eral months 1 Follow all the instructions in the “Care” section of this chapter 2. For motoreycles equipped with a fuel cock that has an “OFF” pos- tron’ Turn the fuel oock lever to “OFF 79 8. Drain the carburetor float chamber by loosening the drain bott, this will prevent fuel deposits from building Up. Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro- tect the cylinders, piston nngs, ete. from corrosion a Remove the spark plug caps and spark plugs b Poura teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded (This wil imit spark- ing during the next step ) 4 Tum the engine over several times with the starter. (This wall coat the cylinder walls with oll.) @ Remove the spark plug caps