yzf600 thundercat

PRINTED IN JAPAN2001 . 6 - 0.3 × 1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

4TV-28199-E6

OWNER’S MANUAL

YZF600R

Shiro.fm Page 1 Thursday, June 7, 2001 11:38 AM

03338 INTRODUCTION

Yamaha’s vast experience andcture of high-quality products,

bility.

o as to enjoy all advantages ofnstruct you in how to operate, to safeguard yourself and oth-

lp keep your motorcycle in theions, do not hesitate to contact

nt rides. So, remember to put

U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM

EAU

Welcome to the Yamaha world of motorcycling!

As the owner of a YZF600R, you are benefiting fromnewest technology regarding the design and manufawhich have earned Yamaha a reputation for dependa

Please take the time to read this manual thoroughly, syour YZF600R. The owner’s manual does not only iinspect and maintain your motorcycle, but also in howers from trouble and injury.

In addition, the many tips given in this manual will hebest possible condition. If you have any further questyour Yamaha dealer.

The Yamaha team wishes you many safe and pleasasafety first!

EAU00005PORTANT MANUAL INFORMATION

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

ERT! YOUR SAFETY IS


IM

Par

re injury or death to theting or repairing the

to avoid damage to the

learer.

torcycle and should remain

d quality. Therefore, whilelable at the time of printing,d this manual. If you haveaha dealer.

C

N

The Safety Alert Symbol meINVOLVED!

WARNING Failure to follow WARNING inmotorcycle operator, a bymotorcycle.

AUTION: A CAUTION indicates specialmotorcycle.

OTE: A NOTE provides key informati

NOTE:_

� This manual should be considwith it even if the motorcycle

� Yamaha continually seeks adthis manual contains the mosthere may be minor discrepaany questions concerning this

_

ans ATTENTION! BECOME AL

structions could result in sevestander, or a person inspec

precautions that must be taken

on to make procedures easier or c

ered a permanent part of this mois subsequently sold.vancements in product design ant current product information avaincies between your motorcycle an manual, please consult your Yam

IMPORTANT MANUAL INFORMATIONEW000002

IS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGE.


WARNING_

PLEASE READ THTHIS MOTORCYCL_

IMPORTANT MANUAL INFORMATION

© 20

Anywit


EAU04229

YZF600ROWNER’S MANUAL

01 by Yamaha Motor Co., Ltd.1st edition, May 2001All rights reserved.

reprinting or unauthorized usehout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan.

LE OF CONTENTS

WAY 1

2

FUNCTIONS 3

4

T RIDING POINTS 5

D MINOR REPAIR 6

ORAGE 7

8

9

EAU00009

U4TVE6.book

TAB

1 GIVE SAFETY THE RIGHT OF

2 DESCRIPTION

3 INSTRUMENT AND CONTROL

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTAN

6 PERIODIC MAINTENANCE AN

7 MOTORCYCLE CARE AND ST

8 SPECIFICATIONS

9 CONSUMER INFORMATION

Page 1 Saturday, August 4, 2001 12:14 PM

INDEX

GIVE SAFETY THE RIGHT OF WAY

1

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


1

EAU00021

nsurpassed feeling of power andt accept; even the best motorcycle


e and operating condition of youre for the rider: good performanceedication, drugs and alcohol is, ofrs—must always be at their mentallcohol, there is a tendency to take

eat belts are for car drivers and made of leather or tear-resistantves and a properly fitting helmet.

elessness. Although full-coverage and protection, motorcyclists willrisk of going too fast and are apt tohe good motorcyclist rides safely, caused by others.

1-1

1-GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an ufreedom. However, they also impose certain limits, which you musdoes not ignore the laws of physics.

Regular care and maintenance are essential for preserving valumotorcycle. Moreover, what is true for the motorcycle is also trudepends on being in good shape. Riding under the influence of mcourse, out of the question. Motorcycle riders—more than car driveand physical best. Under the influence of even small amounts of adangerous risks.

Protective clothing is as essential for the motorcycle rider as spassengers. Always wear a complete motorcycle suit (whethersynthetic materials with protectors), sturdy boots, motorcycle gloOptimum protective wear, however, should not encourage carhelmets and suits, in particular, create an illusion of total safetyalways be vulnerable. Riders who lack critical self-control run the take chances. This is even more dangerous in wet weather. Tpredictably and defensively—avoiding all dangers, including those

Enjoy your ride!

DESCRIPTION

2

Left view ............................................................................................. 2-1Right view........................................................................................... 2-2Controls and instruments ................................................................... 2-3


2

EAU00026


2-DE

Le

1.2.3.4.5.

6.7.8.9.

10.
2-1
SCRIPTION

ft view

Air intake duct (page 6-19)Fuel tank (page 3-8)Shock absorber assembly spring preload adjusting ring (page 3-15)Shock absorber assembly rebound damping force adjusting knob (page 3-15)Shock absorber assembly compression damping force adjusting screw (page 3-16)Storage compartment (page 3-12)Helmet holder (page 3-12)Grab barShift pedal (page 3-7)Radiator (page 6-15)

DESCRIPTION

2

R

11121314151617181920


2-2

ight view

. Luggage strap holders (page 3-18)

. Rear brake fluid level check window (page 6-28)

. Coolant reservoir (page 6-13)

. Front fork spring preload adjusting bolt (page 3-13)

. Front fork rebound damping force adjusting screw (page 3-14)

. Radiator cap (page 6-15)

. Front fork compression damping force adjusting screw (page 3-14)

. Engine oil level check window (page 6-10)

. Brake pedal (page 3-8)

. Engine oil filler cap (page 6-10)

DE

2

Co

1.2.3.4.5.6.7.8.9.

10.


SCRIPTION

2-3

ntrols and instruments

Clutch lever (page 3-7)Left handlebar switches (page 3-5)Starter (choke) lever (page 3-11)Speedometer unit (page 3-3)Tachometer (page 3-4)Coolant temperature gauge (page 3-5)Right handlebar switches (page 3-6)Brake lever (page 3-7)Throttle grip (page 6-20)Main switch/steering lock (page 3-1)

3

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock .....................................3-1Indicator and warning lights ................................3-2Speedometer unit ................................................3-3Tachometer ..........................................................3-4Self-diagnosis device ...........................................3-4Coolant temperature gauge .................................3-5Anti-theft alarm (optional) ....................................3-5Handlebar switches .............................................3-5Clutch lever ..........................................................3-7Shift pedal ............................................................3-7Brake lever ...........................................................3-7Brake pedal ..........................................................3-8Fuel tank cap .......................................................3-8

Fuel ..................................................................... 3-9Fuel tank breather hose (for Germany only) ..... 3-10Starter (choke) lever .......................................... 3-11Seat ................................................................... 3-11Helmet holder .................................................... 3-12Storage compartment ....................................... 3-12Adjusting the front fork ...................................... 3-13Adjusting the shock absorber assembly ............ 3-15Matching the front and rear suspension

settings ............................................................ 3-17Luggage strap holders ...................................... 3-18Sidestand .......................................................... 3-18Ignition circuit cut-off system ............................. 3-19


3

EAU00027


3-IN

EW000016

WARNINGer turn the key to “OFF” orCK” while the motorcycle is

ving, otherwise the electricaltems will be switched off, whichy result in loss of control or anident. Make sure that the motor-le is stopped before turning the to “OFF” or “LOCK”.

ush.urn.

MaThethe usepos

ONAll powThe

OFAll can

3-1

STRUMENT AND CONTROL FUNCTIONS

EAU00029

in switch/steering lock main switch/steering lock controlsignition and lighting systems, and isd to lock the steering. The variousitions are described below.

EAU00036

electrical systems are supplied wither, and the engine can be started. key cannot be removed.

EAU00038

Felectrical systems are off. The key be removed.

EAU00040

LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

To lock the steering1. Turn the handlebars all the way to

the left.2. Push the key in from the “OFF” po-

sition, and then turn it to “LOCK”while still pushing it.

3. Remove the key.

To unlock the steeringPush the key in, and then turn it to“OFF” while still pushing it.

_

Nev“LOmosysmaacccyckey_

1. P2. T

NTROL FUNCTIONS

3

ThanelbeThke

C_

Danw_

. Set the engine stop switch to “ ”and turn the key to “ON”.

. Shift the transmission into the neu-tral position or pull the clutch lever.

. Push the start switch. If the warn-ing light does not come on whilepushing the start switch, have aYamaha dealer check the electri-cal circuit.

TE:en if the oil level is sufficient, therning light may flicker when riding on

slope or during sudden acceleration deceleration, but this is not a mal-nction.


INSTRUMENT AND CO

3-2

EAU01590

(Parking)e steering is locked, and the taillightd auxiliary light are on, but all other

ectrical systems are off. The key can removed.e steering must be locked before they can be turned to “ ”.

ECA00043

AUTION:o not use the parking position for extended length of time, other-

ise the battery may discharge.

EAU03034

Indicator and warning lights

EAU00061

Neutral indicator light “ ” This indicator light comes on when thetransmission is in the neutral position.

EAU03201

Oil level warning light “ ” This warning light comes on when theengine oil level is low.The electrical circuit of the warning lightcan be checked according to the fol-lowing procedure.

1

2

3

NO_

Evwaa orfu_

1. Neutral indicator light “ ”2. Oil level warning light “ ”3. Fuel level warning light “ ”4. Turn signal indicator light “ ”5. High beam indicator light “ ”

IN

3

FuThifue3.1as Thecanlow

1.

2.

EAU00095

eedometer unit speedometer unit is equipped withpeedometer, an odometer and ameter. The speedometer showsng speed. The odometer shows thel distance traveled. The tripmeterws the distance traveled since it last set to zero with the reset knob. tripmeter can be used to estimate

distance that can be traveled with atank of fuel. This information will en-e you to plan future fuel stops.

1. N2. O3. F4. T5. H

dometerripmeter reset knobripmeter



3-3

EAU03509

el level warning light “ ” s warning light comes on when thel level drops below approximately L . When this occurs, refuel as soonpossible. electrical circuit of the warning light be checked according to the fol-ing procedure.Set the engine stop switch to “ ”and turn the key to “ON”. Shift the transmission into the neu-tral position or pull the clutch lever.

3. Push the start switch. If the warn-ing light does not come on, have aYamaha dealer check the electri-cal circuit.

NOTE:_

This model is equipped with a self-di-agnosis device for the fuel level warn-ing light circuit. (See page 3-4 for anexplanation of the self-diagnosis de-vice.) _

EAU00057

Turn signal indicator light “ ” This indicator light flashes when theturn signal switch is pushed to the leftor right.

EAU00063

High beam indicator light “ ” This indicator light comes on when thehigh beam of the headlight is switchedon.

SpThea stripriditotashowasThethefull abl

eutral indicator light “ ”il level warning light “ ”uel level warning light “ ”urn signal indicator light “ ”igh beam indicator light “ ”

1. O2. T3. T

NTROL FUNCTIONS

3

TThtow

C_

DchR_

the tachometer displays such an er-r code, note the circuit-specific num-r of r/min, and then have a Yamahaaler check the motorcycle.

EC000004

AUTION:hen the tachometer displays anror code, the motorcycle should checked as soon as possible inder to avoid engine damage. 1.

2.


INSTRUMENT AND CO

3-4

EAU00101

achometer e electric tachometer allows the rider

monitor the engine speed and keep itithin the ideal power range.

EC000003

AUTION:o not operate the engine in the ta-ometer red zone.

ed zone: 13,200 r/min and above

EAU00105

Self-diagnosis device This model is equipped with a self-di-agnosis device for the following electri-cal circuits:

� throttle position sensor� fuel level warning light

If any of those circuits are defective,the tachometer will repeatedly displaythe following error code:CB-11E

Use the table below to identify thefaulty electrical circuit.CB-12E

If robede

C_

Werbeor_

TachometerTachometer red zone

Specific r/min Faulty electrical circuit

3,000 r/min Throttle position sensor

8,000 r/min Fuel level warning light

0 r/min for 3 seconds

Circuit-specific number of r/min for 2.5 seconds (See the table below.)

Current engine speed for 3 seconds

IN

3

CoWitcoothecooes thezonengins

CA_

Doove_

EAU00118

ndlebar switches

EAU00120

s switch “PASS” ss this switch to flash the headlight.

EAU03888

mer switch “ / ” this switch to “ ” for the highm and to “ ” for the low beam.

1. C2. C

ass switch “PASS”immer switch “ / ”urn signal switch “ / ”orn switch “ ”



3-5

EAU01652

olant temperature gauge h the key in the “ON” position, thelant temperature gauge indicates temperature of the coolant. Thelant temperature varies with chang-in the weather and engine load. If needle reaches or enters the rede, stop the motorcycle and let theine cool. (See page 6-45 for further

tructions.)EC000002

UTION: not operate the engine if it isrheated.

EAU00109

Anti-theft alarm (optional) This motorcycle can be equipped withan optional anti-theft alarm by aYamaha dealer. Contact a Yamahadealer for more information.

Ha

PasPre

DimSetbea

oolant temperature gaugeoolant temperature gauge red zone

1. P2. D3. T4. H

NTROL FUNCTIONS

3

TuToswtureteligtu

HPr

EAU00143

art switch “ ” sh this switch to crank the engine

th the starter.EC000005

AUTION:e page 5-1 for starting instruc-ns prior to starting the engine.


INSTRUMENT AND CO

3-6

EAU03889

rn signal switch “ / ” signal a right-hand turn, push thisitch to “ ”. To signal a left-hand

rn, push this switch to “ ”. Whenleased, the switch returns to the cen-r position. To cancel the turn signalhts, push the switch in after it has re-rned to the center position.

EAU00129

orn switch “ ” ess this switch to sound the horn. EAU03890

Engine stop switch “ / ” Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the motorcycle over-turns or when the throttle cable isstuck.

EAU03898

Light switch “ / / ” Set this switch to “ ” to turn on theauxiliary light, meter lighting and tail-light. Set the switch to “ ” to turn onthe headlight also. Set the switch to“ ” to turn off all the lights.

StPuwi

C_

Setio_

1. Engine stop switch “ / ”2. Light switch “ / / ”3. Start switch “ ”

IN

3

ClThehanclubartherapcluTheclucircfor cut

EAU00161

ke lever brake lever is located at the rightdlebar grip. To apply the front brake,the lever toward the handlebar grip. brake lever is equipped with a po-n adjusting dial. To adjust the dis-e between the brake lever and thedlebar grip, turn the adjusting diale holding the lever pushed away the handlebar grip. Make sure that

appropriate setting on the adjustingis aligned with the arrow mark onbrake lever.

1. C row markake lever position adjusting dialake leveristance between brake lever and handlebar ip



3-7

EAU00152

utch lever clutch lever is located at the leftdlebar grip. To disengage the

tch, pull the lever toward the handle- grip. To engage the clutch, release lever. The lever should be pulledidly and released slowly for smoothtch operation. clutch lever is equipped with a

tch switch, which is part of the ignitionuit cut-off system. (See page 3-19an explanation of the ignition circuit-off system.)

EAU00157

Shift pedal The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 6-speed con-stant-mesh transmission equipped onthis motorcycle.

BraThehanpull Thesitiotanchanwhilfromthe dial the

lutch lever 1. Shift pedal 1. Ar2. Br3. Bra. D

gr

NTROL FUNCTIONS

3

BThthbr

. Turn the key counterclockwise tothe original position, remove it,and then close the lock cover.

TE:e fuel tank cap cannot be closed un-s the key is in the lock. In addition,

e key cannot be removed if the cap ist properly closed and locked.

EWA00025

WARNINGake sure that the fuel tank cap isoperly closed before riding.

1.


INSTRUMENT AND CO

3-8

EAU00162

rake pedal e brake pedal is on the right side of

e motorcycle. To apply the rearake, press down on the brake pedal.

EAU02935

Fuel tank cap

To open the fuel tank capOpen the fuel tank cap lock cover, in-sert the key into the lock, and then turnit 1/4 turn clockwise. The lock will be re-leased and the fuel tank cap can beopened.

To close the fuel tank cap1. Push the fuel tank cap into posi-

tion with the key inserted in thelock.

2

NO_

Thlesthno_

_

Mpr_

Brake pedal 1. Fuel tank cap lock cover2. Unlock.

IN

3

FuMatheof t

_

�

�

_

ECA00104

UTION: only unleaded gasoline. The of leaded gasoline will cause se-e damage to internal enginets, such as the valves and pistons, as well as to the exhaust sys-.

r Yamaha engine has been de-ed to use regular unleaded gaso-

with a research octane number ofor higher. If knocking (or pinging)urs, use a gasoline of a differentnd or premium unleaded fuel. Usenleaded fuel will extend spark plugand reduce maintenance costs.

1. F2. F



3-9

EAU03753

el ke sure that there is sufficient fuel in tank. Fill the fuel tank to the bottomhe filler tube as shown.

EW000130

WARNINGDo not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands. Avoid spilling fuel on the hotengine.

EAU00186

CAUTION:_

� Immediately wipe off spilled fuelwith a clean, dry, soft cloth,since fuel may deteriorate paint-ed surfaces or plastic parts.

� For Germany only: Wheneverreplacement is necessary, use afuel tank cap of the same spe-cial design as the original.

_

EAU04255

CA_

Useuseverparringtem_

Yousignline91 occbraof ulife

uel tank filler tubeuel level

Recommended fuel:REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:Total amount:

19 LReserve amount:

3.1 L

NTROL FUNCTIONS

3

F(fBe


INSTRUMENT AND CO

3-10

EAU00196

uel tank breather hose or Germany only) fore operating the motorcycle:

� Check the fuel tank breather hoseconnection.

� Check the fuel tank breather hosefor cracks or damage, and replaceit if damaged.

� Make sure that the end of the fueltank breather hose is not blockedand clean it if necessary.

1. Fuel tank breather hose

IN

3

StStaair-theMotheMothe

EAU04158

move the seatsert the key into the helmet hold-r lock, and then turn it as shown.ull the seat off.

1. S ck.



3-11

EAU02973

arter (choke) lever “ ” rting a cold engine requires a richerfuel mixture, which is supplied by starter (choke).ve the lever in direction a to turn on starter (choke).ve the lever in direction b to turn off starter (choke).

ECA00038

CAUTION:_

Do not use the starter (choke) formore than 3 minutes as the exhaustpipe may discolor from excessiveheat. In addition, extended use ofthe starter (choke) will cause after-burning. If this occurs, turn off thestarter (choke). _

Seat

To re1. In

e2. P

tarter (choke) lever “ ” 1. Unlo

NTROL FUNCTIONS

3

To1

2

3

N_

Mcu_

EAU04275

rage compartment storage compartment is designedold an optional genuine Yamaha U-K. (Other locks may not fit.) Whening a U-LOCK in the storage com-ment, securely fasten it with theps. When the U-LOCK is not in theage compartment, be sure to se- the straps to prevent losing them.

en storing the owner’s manual orr documents in the storage com-ment, be sure to wrap them in atic bag so that they will not get wet.

en washing the motorcycle, beful not to let any water enter theage compartment.

1.2.

-LOCK bartrap (× 3)ck of the U-LOCK


INSTRUMENT AND CO

3-12

install the seat. Insert the projections on the front

of the seat into the seat holder asshown.

. Push the rear of the seat down tolock it in place.

. Remove the key.

OTE:ake sure that the seat is properly se-red before riding.

EAU00261

Helmet holder To open the helmet holder, insert thekey into the lock, and then turn the keyas shown.To lock the helmet holder, turn the keyto the original position, and then re-move it.

EW000030

WARNING_

Never ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss ofcontrol and possibly an accident. _

StoThisto hLOCplacpartstrastorcureWhothepartplasWhcarestor

Seat holderProjection (× 2)

1. Helmet holder2. Unlock.

1. U2. S3. Lo

IN

3

AdThipreingprescr

_

Alwly, of _

TE:n the appropriate groove on the ad-ing mechanism with the top of thet fork cap bolt.

urrent settingront fork cap bolt

Setting

Minimum (soft) 8

Standard 5

Maximum (hard) 1



3-13

EAU01862

justing the front fork s front fork is equipped with springload adjusting bolts, rebound damp- force adjusting screws and com-ssion damping force adjustingews.

EW000035

WARNINGays adjust both fork legs equal-

otherwise poor handling and lossstability may result.

Spring preloadTo increase the spring preload andthereby harden the suspension, turnthe adjusting bolt on each fork leg in di-rection a. To decrease the spring pre-load and thereby soften thesuspension, turn the adjusting bolt oneach fork leg in direction b.

NO_

Aligjustfron_

CI-10E

1. Spring preload adjusting bolt 1. C2. F

NTROL FUNCTIONS

3

RTofodaeacrthtuleCI-

EC000015

AUTION:ver attempt to turn an adjusting

echanism beyond the maximum minimum settings.

TE:though the total number of clicks of amping force adjusting mechanismay not exactly match the above spec-ations due to small differences in

oduction, the actual number of clicksays represents the entire adjusting

nge. To obtain a precise adjustment,ould be advisable to check the num-

r of clicks of each damping force ad-ting mechanism and to modify theecifications as necessary.

1.

M

* W


INSTRUMENT AND CO

3-14

ebound damping force increase the rebound damping

rce and thereby harden the reboundmping, turn the adjusting screw onch fork leg in direction a. To de-ease the rebound damping force andereby soften the rebound damping,rn the adjusting screw on each forkg in direction b.02E

Compression damping forceTo increase the compression dampingforce and thereby harden the compres-sion damping, turn the adjusting screwon each fork leg in direction a. To de-crease the compression damping forceand thereby soften the compressiondamping, turn the adjusting screw oneach fork leg in direction b.CI-02E

C_

Nemor_

NO_

Aldamificpralwrait wbejussp_

Rebound damping force adjusting screw

Minimum (soft) 10 clicks in direction b*

Standard 7 clicks in direction b*

aximum (hard) 1 click in direction b*

ith the adjusting screw fully turned in direction a

1. Compression damping force adjusting screw

Minimum (soft) 10 clicks in direction b*


Maximum (hard) 1 click in direction b*

* With the adjusting screw fully turned in direction a

IN

3

AdasThiequingjusdam

CA_

Neloajusma_

ound damping forceincrease the rebound damping

e and thereby harden the reboundping, turn the adjusting knob in di-

tion a. To decrease the reboundping force and thereby soften the

ound damping, turn the adjustingb in direction b.

ebound damping force adjusting knob

inimum (soft) 25 clicks in direction b*


ximum (hard) 3 clicks in direction b*

th the adjusting knob fully turned in direction a



3-15

EAU03643

justing the shock absorber sembly s shock absorber assembly isipped with a spring preload adjust-

ring, a rebound damping force ad-ting knob and a compression

ping force adjusting screw.ECA00071

UTION:ver attempt to turn the spring pre-d and rebound damping force ad-ting mechanisms beyond theximum or minimum settings.

Spring preloadTo increase the spring preload andthereby harden the suspension, turnthe adjusting ring in direction a. To de-crease the spring preload and therebysoften the suspension, turn the adjust-ing ring in direction b.CI-10E

RebTo forcdamrecdamrebknoCI-03E

1. Spring preload adjusting ring2. Position indicator

Setting

Minimum (soft) 1

Standard 3

Maximum (hard) 7

1. R

M

Ma

* Wi

NTROL FUNCTIONS

3

N_

Althmabfebeencitobonias_

EAU00315

WARNINGis shock absorber contains high-

pressurized nitrogen gas. Foroper handling, read and under-and the following information be-re handling the shock absorber.e manufacturer cannot be held re-onsible for property damage orrsonal injury that may result fromproper handling.

� Do not tamper with or attempt toopen the gas cylinder.

� Do not subject the shock ab-sorber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.

� Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

� Always have a Yamaha dealerservice the shock absorber.


INSTRUMENT AND CO

3-16

OTE:though the total number of clicks ofe rebound damping force adjustingechanism may not exactly match theove specifications due to small dif-rences in production, the actual num-r of clicks always represents thetire adjusting range. To obtain a pre-

se adjustment, it would be advisable check the number of clicks of the re-und damping force adjusting mecha-

sm and to modify the specifications necessary.

Compression damping forceTo harden the compression damping,decrease the setting by turning the ad-justing screw. To soften the compres-sion damping, increase the setting byturning the adjusting screw. Make surethat the position indicator is alignedwith the appropriate setting.CI-10E

_

ThlyprstfoThsppeim

_

1. Compression damping force adjusting screw2. Position indicator

Setting

Minimum (soft) 6

Standard 4

Maximum (hard) 1

IN

3

EAU01580

MaUs t fork and shock absorber assemblyaccCI-05

EC000015

CA_

Ne settings. _

L bsorber assembly adjustment

Compression damping force

Rebound damping force

1–6 3–25

W 1–4 3–10



3-17

tching the front and rear suspension settings e this table as a guide to match the suspension and damping adjustments of the fronording to various load conditions.

E

UTION:ver attempt to turn an adjusting mechanism beyond the maximum or minimum

oad condition Front fork adjustment Shock a

Spring preloadCompression damping force

Rebound damping force

Spring preload

Rider only 1–8 1–10 1–10 1–5

ith passenger 1–8 1–10 1–10 3–7

NTROL FUNCTIONS

3

LThtwie

EW000044

WARNINGe motorcycle must not be ridden

ith the sidestand down, or if thedestand cannot be properlyoved up (or does not stay up), oth-wise the sidestand could contacte ground and distract the opera-r, resulting in a possible loss ofntrol. Yamaha’s ignition circuitt-off system has been designed tosist the operator in fulfilling thesponsibility of raising the side-and before starting off. Therefore,eck this system regularly as de-ribed below and have a Yamahaaler repair it if it does not functionoperly.

1.

L


INSTRUMENT AND CO

3-18

EAU04276

uggage strap holders ere are four luggage strap holders,o of which can be turned out for eas-r access.

EAU00330

Sidestand The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding themotorcycle upright.

NOTE:_

The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.) _

_

Thwsimerthtococuasrestchscdepr_

Luggage strap holder (× 4)

eft Right

IN

3

IgnTheprisswlow

�

�

�

Peignto t

_

If Yabef_



3-19

EAU03720

ition circuit cut-off system ignition circuit cut-off system (com-ing the sidestand switch, clutch

itch and neutral switch) has the fol-ing functions.It prevents starting when the trans-mission is in gear and the side-stand is up, but the clutch lever isnot pulled.It prevents starting when the trans-mission is in gear and the clutchlever is pulled, but the sidestand isstill down.It cuts the running engine whenthe transmission is in gear and thesidestand is moved down.

riodically check the operation of theition circuit cut-off system accordinghe following procedure.

EW000045

WARNINGa malfunction is noted, have amaha dealer check the systemore riding.

NTROL FUNCTIONS

3

CD

witch may be defective.cle should not be ridden until Yamaha dealer.

d switch may be defective.cle should not be ridden until Yamaha dealer.

itch may be defective.cle should not be ridden until Yamaha dealer.

most reliable if performed with engine.


INSTRUMENT AND CO

3-20

-01E

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “ ”.3. Turn the key to “ON”. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

The neutral sThe motorcychecked by a

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?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The sidestanThe motorcychecked by a

The clutch swThe motorcychecked by a

NO

NOTE:This check isa warmed-up

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

PRE-OPERATION CHECKS

4

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


4

EAU01114

teriorate quickly and unexpectedly,). Any damage, fluid leakage or lossddition to a thorough visual inspec-


4-PR

Theeveof ti

EAU03439

PAGE

3-9

6-10

6-13–6-14

6-27–6-28

6-25–6-28

6-25

tion

CO-01E

Fu

En

Co

Fro

Re

Clu

4-1

E-OPERATION CHECKS

condition of a vehicle is the owner’s responsibility. Vital components can start to den if the vehicle remains unused (for example, as a result of exposure to the elementsre air pressure could have serious consequences. Therefore, it is very important, in a, to check the following points before each ride.

Pre-operation check list

ITEM CHECKS

el• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

gine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

olant• Check coolant level in reservoir.• If necessary, add recommended coolant to specified level.• Check cooling system for leakage.

nt brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

ar brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

tch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

PERATION CHECKS

4

T 6-20

C 6-31

D 6-29, 6-30

W 6-21–6-24

B 6-31

B 6-32

S 6-32

C —

Ina —

S 3-18

A 6-19

PAGE


PRE-O

4-2

hrottle grip• Make sure that operation is smooth.• Check free play.• If necessary, have Yamaha dealer make adjustment or lubricate.

ontrol cables • Make sure that operation is smooth.• Lubricate if necessary.

rive chain

• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

heels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

rake and shift pedals • Make sure that operation is smooth.• Lubricate pedal pivoting points if necessary.

rake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary.

idestand • Make sure that operation is smooth.• Lubricate pivot if necessary.

hassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary.

struments, lights, signals nd switches

• Check operation. • Correct if necessary.

idestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle.

ir intake duct • Check that the screen is not clogged.• Clean if necessary.

ITEM CHECKS

PR

4

NO_

Pre ction can be accomplished in a verysho_

EWA00033

_

If a ed and repaired before operatingthe_


E-OPERATION CHECKS

4-3

TE:-operation checks should be made each time the motorcycle is used. Such an inspert time; and the added safety it assures is more than worth the time involved.

WARNINGny item in the Pre-operation check list is not working properly, have it inspect motorcycle.

OPERATION AND IMPORTANT RIDING POINTS

5

Starting the engine ............................................................................ 5-1Starting a warm engine ..................................................................... 5-3Shifting .............................................................................................. 5-3Recommended shift points (for Switzerland only) ............................. 5-4Tips for reducing fuel consumption ................................................... 5-4Engine break-in ................................................................................. 5-5Parking .............................................................................................. 5-6


5

EAU00372

EC000035

UTION:e fuel level warning light comes


5-OP

_

�

check the fuel level, and, if nec-ary, refuel as soon as possible.

Shift the transmission into the neu-tral position.

TE:en the transmission is in the neutralition, the neutral indicator lightuld be on, otherwise have aaha dealer check the electrical cir-

.

Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-11 for starter (choke) oper-ation.)Start the engine by pushing thestart switch.

�

�

_

5-1

ERATION AND IMPORTANT RIDING POINTSEAU00373

WARNINGBecome thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU03818*

Starting the engine In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

� The transmission is in the neutralposition.

� The transmission is in gear withthe clutch lever pulled and thesidestand up.

EW000054

WARNING_

� Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-20.

� Never ride with the sidestanddown.

_

1. Turn the key to “ON” and makesure that the engine stop switch isset to “ ”.

CA_

If thon,ess_

2.

NO_

WhposshoYamcuit_

3.

4.

ANT RIDING POINTS

5

N_

If stthshsegiat_

C_

. When the engine is warm, turn thestarter (choke) off.

TE:e engine is warm when it respondsrmally to the throttle with the starter

hoke) turned off.


OPERATION AND IMPORT

5-2

OTE:the engine fails to start, release theart switch, wait a few seconds, anden try again. Each starting attemptould be as short as possible to pre-rve the battery. Do not crank the en-

ne more than 10 seconds on any onetempt.

EC000038

AUTION:� The oil level warning light and

fuel level warning light shouldcome on when the start switchis pushed, and they should gooff when the start switch is re-leased.

� If the oil level warning light flick-ers or remains on after starting,immediately stop the engine,and then check the engine oillevel and the vehicle for oil leak-age. If necessary, add engineoil, and then check the warninglight again. If the warning lightdoes not come on when push-ing the start switch, or if it does

not go off after starting with suf-ficient engine oil, have aYamaha dealer check the elec-trical circuit.

� If the fuel level warning light re-mains on after starting, stop theengine, and then check the fuellevel. If necessary, refuel assoon as possible, and thencheck the warning light again. Ifthe warning light does not comeon when pushing the startswitch, or if it does not go off af-ter starting with sufficient fuel,have a Yamaha dealer check theelectrical circuit.

_

5. After starting the engine, move thestarter (choke) lever back halfway.

ECA00045

CAUTION:_

For maximum engine life, never ac-celerate hard when the engine iscold! _

6

NO_

Thno(c_

O

5

StFolingthawh

EC000048

UTION:Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.Always use the clutch whilechanging gears to avoid dam-aging the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.


PERATION AND IMPORTANT RIDING POINTS

5-3

EAU01258

arting a warm engine low the same procedure as for start- a cold engine with the exceptiont the starter (choke) is not requireden the engine is warm.

EAU00423

Shifting Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

NOTE:_

To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it. _

CA_

�

�

_

1. Shift pedalN. Neutral position

ANT RIDING POINTS

5

R(fThacloCF

N_

Wtim(efro_



5-4

EAU02937

ecommended shift points or Switzerland only) e recommended shift points duringceleration are shown in the table be-

w.-02E

OTE:hen shifting down two gears at ae, reduce the speed accordingly

.g., down to 35 km/h when shiftingm 5th to 3rd gear).

EAU00424

Tips for reducing fuel consumption Fuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

� Thoroughly warm up the engine.� Turn the starter (choke) off as

soon as possible.� Shift up swiftly, and avoid high en-

gine speeds during acceleration.� Do not rev the engine while shift-

ing down, and avoid high enginespeeds with no load on the engine.

� Turn the engine off instead of let-ting it idle for an extended lengthof time (e.g., in traffic jams, at traf-fic lights or at railroad crossings).

Shift point(km/h)

1st → 2nd2nd → 3rd3rd → 4th4th → 5th5th → 6th

2030405060

O

5

EnThein tbetsonteriSinput1,6gincorthisatioin e

EC000053

UTION:Keep the engine speed out ofthe tachometer red zone.If any engine trouble should oc-cur during the engine break-inperiod, immediately have aYamaha dealer check the vehi-cle.


PERATION AND IMPORTANT RIDING POINTS

5-5

EAU01128

gine break-in re is never a more important period

he life of your engine than the periodween 0 and 1,600 km. For this rea-, you should read the following ma-al carefully.ce the engine is brand new, do not an excessive load on it for the first00 km. The various parts in the en-e wear and polish themselves to therect operating clearances. During period, prolonged full-throttle oper-n or any condition that might resultngine overheating must be avoided.

EAU03749*

0–1,000 kmAvoid prolonged operation above6,500 r/min.

1,000–1,600 kmAvoid prolonged operation above8,000 r/min.

EC000052*

CAUTION:_

After 1,000 km of operation, the en-gine oil must be changed and the oilfilter cartridge replaced. _

1,600 km and beyondThe vehicle can now be operated nor-mally.

CA_

�

�

_

ANT RIDING POINTS

5

PWthsw

_

_



5-6

EAU00460

arking hen parking, stop the engine, anden remove the key from the mainitch.

EW000058

WARNING� Since the engine and exhaust

system can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

� Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1Periodic maintenance and lubrication chart .........6-2Removing and installing cowlings ........................6-5Checking the spark plugs ....................................6-8Engine oil and oil filter cartridge ........................6-10Coolant ..............................................................6-13Cleaning the air filter element ............................6-17Checking the air vent hose ................................6-18Air intake duct ....................................................6-19Adjusting the carburetors ...................................6-19Adjusting the engine idling speed ......................6-19Adjusting the throttle cable free play ..................6-20Adjusting the valve clearance ............................6-20Tires ...................................................................6-21Cast wheels .......................................................6-24Adjusting the clutch lever free play ....................6-25Adjusting the brake pedal position .....................6-25Adjusting the rear brake light switch ..................6-26Checking the front and rear brake pads .............6-27Checking the brake fluid level ............................6-27Changing the brake fluid ....................................6-28Drive chain slack ................................................6-29Lubricating the drive chain .................................6-30

Checking and lubricating the cables ................. 6-31Checking and lubricating the throttle grip and

cable ............................................................... 6-31Checking and lubricating the brake and shift

pedals ............................................................. 6-31Checking and lubricating the brake and clutch

levers ............................................................... 6-32Checking and lubricating the sidestand ............ 6-32Lubricating the rear suspension ........................ 6-32Checking the front fork ...................................... 6-33Checking the steering ....................................... 6-33Checking the wheel bearings ............................ 6-34Battery ............................................................... 6-35Replacing the fuses .......................................... 6-36Replacing the headlight bulb ............................. 6-37Replacing the tail/brake light bulb ..................... 6-38Replacing a turn signal light bulb ...................... 6-39Supporting the motorcycle ................................ 6-39Front wheel ....................................................... 6-40Rear wheel ........................................................ 6-41Troubleshooting ................................................. 6-43Troubleshooting charts ...................................... 6-44


6

EAU00462

TE:ou do not have the tools or experi-e required for a particular job, have


6-PE

SafPer

amaha dealer perform it for you.

EW000063

WARNINGdifications not approved by

aha may cause loss of perfor-nce and render the vehicle un-e for use. Consult a Yamahaler before attempting any chang-

bricsafesiblspeareThemashoerationWECAUSVALEN

_

If ycycYam_

6-1

RIODIC MAINTENANCE AND MINOR REPAIR EAU00464

ety is an obligation of the owner.iodic inspection, adjustment and lu-ation will keep your vehicle in thest and most efficient condition pos-

e. The most important points of in-ction, adjustment, and lubrication explained on the following pages. intervals given in the periodic

intenance and lubrication chartuld be simply considered as a gen-l guide under normal riding condi-s. However, DEPENDING ON THEATHER, TERRAIN, GEOGRAPHI-L LOCATION, AND INDIVIDUALE, THE MAINTENANCE INTER-S MAY NEED TO BE SHORT-

ED.EW000060

WARNINGou are not familiar with motor-le maintenance work, have aaha dealer do it for you.

EAU01299

Owner’s tool kit The owner’s tool kit is located insidethe storage compartment under theseat. (See page 3-11 for seat removalprocedures.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NO_

If yenca Y_

_

MoYammasafdeaes._

1. Owner’s tool kit

AND MINOR REPAIR

6

EAU03685

art

N_

maintenance is performed instead.

equire special tools, data and techni-

_

CP-03E

NETER READING (× 1,000 km) ANNUAL

CHECK10 20 30 40

1 √ √ √ √ √

2 √ √

3√ √

√ √

4 Every 40,000 km

5√ √

√ √

6 √ √ √ √

7√ √ √ √ √

Whenever worn to the limit

8√ √ √ √ √

Whenever worn to the limit


PERIODIC MAINTENANCE

6-2

Periodic maintenance and lubrication ch

OTE:� The annual checks must be performed every year, except if a kilometer-based � From 50,000 km, repeat the maintenance intervals starting from 10,000 km. � Items marked with an asterisk should be performed by a Yamaha dealer as they r

cal skills.

O. ITEM CHECK OR MAINTENANCE JOBODOM

1

* Fuel line • Check fuel hoses for cracks or damage.

* Fuel filter • Check condition.

Spark plugs• Check condition.• Clean and regap.

• Replace.

* Valves • Check valve clearance.• Adjust.

Air filter element• Clean.

• Replace.

Clutch • Check operation.• Adjust. √

* Front brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) √

• Replace brake pads.

* Rear brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) √

• Replace brake pads.

PE

6

9√ √ √ √ √

Every 4 years

10 √ √ √ √

11 √ √ √ √ √

12 √ √ √ √

13√ √ √ √

Every 50,000 km

14 Every 1,000 km and after washingthe motorcycle or riding in the rain

15√ √ √ √

Every 50,000 km

16 √ √ √ √ √

17 √ √ √ √ √

18 √ √ √ √ √

19 √ √ √ √

20 √ √ √ √

21√ √ √ √

√ √

22 √ √ √ √ √

NOTER READING (× 1,000 km) ANNUAL

CHECK10 20 30 40


RIODIC MAINTENANCE AND MINOR REPAIR

6-3

* Brake hoses• Check for cracks or damage.

• Replace. (See NOTE on page 6-4.)

* Wheels • Check runout and for damage.

* Tires

• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

* Wheel bearings • Check bearing for looseness or damage.

* Swingarm• Check operation and for excessive play.

• Lubricate with lithium-soap-based grease.

Drive chain• Check chain slack.• Make sure that the rear wheel is properly aligned.• Clean and lubricate.

* Steering bearings• Check bearing play and steering for roughness. √• Lubricate with lithium-soap-based grease.

* Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.

Sidestand • Check operation.• Lubricate.

* Sidestand switch • Check operation. √

* Front fork • Check operation and for oil leakage.

*Shock absorber assembly • Check operation and shock absorber for oil leakage.

*Rear suspension relay arm and connecting arm pivoting points

• Check operation.

• Lubricate with lithium-soap-based grease.

* Carburetors • Check starter (choke) operation.• Adjust engine idling speed and synchronization. √

. ITEM CHECK OR MAINTENANCE JOBODOME

1

ND MINOR REPAIR

6

EAU03884

N_

reas.

d calipers, and change the brake

_

23 √ √ √ √

24 √ √

25√ √ √ √Every 3 years

26 √ √ √ √

27 √ √ √ √

28 √ √ √ √

NR READING (× 1,000 km) ANNUAL

CHECK0 20 30 40


PERIODIC MAINTENANCE A

6-4

OTE:� The air filter needs more frequent service if you are riding in unusually wet or dusty a� 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 an

fluid.• Replace the brake hoses every four years and if cracked or damaged.

Engine oil • Change.• Check oil level and vehicle for oil leakage. √ √

Engine oil filter cartridge • Replace. √

* Cooling system• Check coolant level and vehicle for coolant leakage. √• Change.

*Front and rear brake switches • Check operation. √ √

Moving parts and cables • Lubricate. √

*Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √

O. ITEM CHECK OR MAINTENANCE JOBODOMETE

1 1

PE

6

RecoTheremten

EAU04277

wlings A and Cremove one of the cowlings

Remove the bolts.

1. C2. C

olt (× 3 on each side)



6-5

EAU01065

moving and installing wlings cowlings shown above need to beoved to perform some of the main-

ance jobs described in this chapter.

Refer to this section each time a cowl-ing needs to be removed and installed.

CoTo

1.

owling Aowling B

1. Cowling C2. Cowling D

1. B

AND MINOR REPAIR

6

. Disconnect the turn signal connec-tors (and, for the left-side cowling,also the auxiliary light coupler),and then take the cowling off.

install the cowling. Connect the turn signal connec-

tors (and, for the left-side cowling,also the auxiliary light coupler).

. Place the cowling in the originalposition, and then install the bolts.

Bo

L

Auxiliary light couplerTurn signal connector (× 2)



6-6

2

To1

2

lt (× 6) Bolt (× 7)

eft side Right side

1. Bolt (× 5 on each side) 1.2.

PE

6

CoTo

1.

2.

NO_

Pumo_

To 1.

2.

tall the cowlinglace the cowling in the originalosition, and then install thecrew.stall the grab bar by installing theolts.stall the cowling and the seat.

1. S



6-7

EAU03595

wling Bremove the cowling

Remove the seat. (See page 3-11for seat removal and installationprocedures.)Remove the screws, and then pullthe cowling off as shown.

TE:ll the cowling up, then back to re-ve it.

install the cowlingPlace the cowling in the originalposition, and then install thescrews.Install the seat.

EAU04278

Cowling DTo remove the cowling

1. Remove the seat and cowling B.(See pages 3-11 and 6-7 for seatand cowling removal and installa-tion procedures.)

2. Remove the grab bar by removingthe bolts.

3. Remove the screw, and then pullthe cowling off as shown.

To ins1. P

ps

2. Inb

3. In

crew (× 2) 1. Bolt (× 2)2. Screw

AND MINOR REPAIR

6

CThcoSispplinnathve

To1

check the spark plugs. Check that the porcelain insulator

around the center electrode oneach spark plug is a medi-um-to-light tan (the ideal colorwhen the motorcycle is ridden nor-mally).

. Check that all spark plugs installedin the engine have the same color.

TE:any spark plug shows a distinctly dif-rent color, the engine could be defec-e. Do not attempt to diagnose suchoblems yourself. Instead, have amaha dealer check the motorcycle.

1.



6-8

EAU03329

hecking the spark plugs e spark plugs are important enginemponents, which are easy to check.nce heat and deposits will cause anyark plug to slowly erode, the spark

ugs should be removed and checked accordance with the periodic mainte-nce and lubrication chart. In addition,e condition of the spark plugs can re-al the condition of the engine.

remove a spark plug. Remove the spark plug cap.

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

To1

2

NO_

If fetivprYa_

Spark plug cap (× 2 on each side) 1. Spark plug wrench

PE

6

3.

TE: torque wrench is not available whenalling a spark plug, a good estimatethe correct torque is 1/4–1/2 turnt finger tight. However, the sparkg should be tightened to the speci- torque as soon as possible.

Install the spark plug cap.

S

ightening torque:Spark plug:

12.5 Nm (1.25 m·kgf)



6-9

Check each spark plug for elec-trode erosion and excessive car-bon or other deposits, and replaceit if necessary.

To install a spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the surface of the sparkplug gasket and its mating sur-face, and then wipe off any grimefrom the spark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NO_

If ainstof pasplufied_

4.

pecified spark plug:CR9E (NGK) orU27ESR-N (DENSO)

a. Spark plug gap

Spark plug gap:0.7–0.8 mm

T

ND MINOR REPAIR

6

EcaThbemtrifielu

To1

N_

Mtiolea _

ange the engine oil (with orut oil filter cartridge replace-

emove cowling A. (See page 6-5r cowling removal and installa-

on procedures.)tart the engine, warm it up foreveral minutes, and then turn itff.lace an oil pan under the engine collect the used oil.

ne oil filler cap



6-10

EAU04279

ngine oil and oil filter rtridge e engine oil level should be checkedfore each ride. In addition, the oilust be changed and the oil filter car-dge replaced at the intervals speci-d in the periodic maintenance andbrication chart.

check the engine oil level. Place the motorcycle on a level

surface and hold it in an uprightposition.

OTE:ake sure that the motorcycle is posi-ned straight up when checking the oilvel. A slight tilt to the side can result infalse reading.

2. Start the engine, warm it up for sev-eral minutes, and then turn it off.

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-right side of thecrankcase.

NOTE:_

The engine oil should be between theminimum and maximum level marks. _

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

To chwithoment)

1. Rfoti

2. Sso

3. Pto

1. Engine oil level check window2. Maximum level mark3. Minimum level mark

1. Engi

PE

6

4.

NO_

Skinot_

Apply a thin coat of engine oil tothe O-ring of the new oil filter car-tridge.

TE:ke sure that the O-ring is properlyted.

Install the new oil filter cartridge,and then tighten it to the specifiedtorque with a torque wrench.

1. E

Le

-ring

ightening torque:Oil filter cartridge:

17 Nm (1.7 m·kgf)



6-11

Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.

TE:p steps 5–7 if the oil filter cartridge is being replaced.

5. Remove the oil filter cartridge withan oil filter wrench.

NOTE:_

An oil filter wrench is available at aYamaha dealer. _

6.

NO_

Masea_

7.

ngine oil drain bolt

ft side

1. Oil filter cartridge2. Oil filter wrench

1. O

T

AND MINOR REPAIR

6

8

9

. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking,immediately turn the engine offand check for the cause.

TE:ter the engine is started, the engine level warning light should go off if the level is sufficient.

EC000067

AUTION:the oil level warning light flickers remains on, immediately turn thegine off and have a Yamaha deal- check the vehicle.

. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

. Install the cowling.



6-12

. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.

. Add the specified amount of therecommended engine oil, andthen install and tighten the oil fillercap.

ECA00105

CAUTION:_

� In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives withthe oil or use oils of grade “CD”or higher. In addition, do notuse oils labeled “ENERGY CON-SERVING II” or higher.

� Make sure that no foreign mate-rial enters the crankcase.

_

10

NO_

Afoiloil_

C_

If orener_

11

12

Tightening torque:Engine oil drain bolt:

43 Nm (4.3 m·kgf)

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter cartridge replacement:

2.6 LWith oil filter cartridge replacement:

2.9 LTotal amount (dry engine):

3.5 L

PE

6

CoThebefantspeand

To1.

NO_

�

�

_

EC000080

UTION:If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine. If water has been used insteadof coolant, replace it with cool-ant as soon as possible, other-wise the engine may not besufficiently cooled and the cool-ing system will not be protectedagainst frost and corrosion. If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possible,otherwise the effectiveness ofthe coolant will be reduced.

oolant reservoir capacity:0.55 L



6-13

EAU03987

olant coolant level should be checked

ore each ride. In addition, the cool- must be changed at the intervalscified in the periodic maintenance lubrication chart.

check the coolant level Place the motorcycle on a levelsurface and hold it in an uprightposition.

TE:The coolant level must be checkedon a cold engine since the levelvaries with engine temperature. Make sure that the motorcycle ispositioned straight up whenchecking the coolant level. A slighttilt to the side can result in a falsereading.

2. Check the coolant level in thecoolant reservoir.

NOTE:_

The coolant should be between theminimum and maximum level marks. _

3. If the coolant is at or below theminimum level mark, remove theseat (See page 3-11 for seat re-moval and installation proce-dures.), and then open the coolantreservoir cap.

4. Add coolant or distilled water toraise the coolant to the specifiedlevel, close the coolant reservoircap, and then install the seat.

CA_

�

�

�

_

1. Maximum level mark2. Minimum level mark

C

ND MINOR REPAIR

6

_

Nto_

N_

_

Remove the fuel tank bolts, andthen lift the fuel tank. (Do not re-move the fuel hoses.)

EW000071

WARNINGMake sure that the fuel tank iswell supported.Do not tilt or pull the fuel tanktoo much, otherwise the fuelhoses may come loose, whichcould cause fuel leakage.

el tank bolt (× 2)



6-14

EW000067

WARNINGever attempt to remove the radia-r cap when the engine is hot.

OTE:� The radiator fan is automatically

switched on or off according to thecoolant temperature in the radia-tor.

� If the engine overheats, seepage 6-45 for further instructions. EAU04280

To change the coolant 1. Place the motorcycle on a level

surface and let the engine cool ifnecessary.

2. Remove the seat. (See page 3-11for seat removal and installationprocedures.)

3. Remove cowling D. (See page 6-7for cowling removal and installa-tion procedures.)

4. Remove the coolant reservoir byremoving the bolts.

5. Drain the coolant from the coolantreservoir.

6. Remove cowlings A and C. (Seepage 6-5 for cowling removal andinstallation procedures.)

7.

_

�

�

_

1. Bolt (× 2)2. Coolant reservoir

1. Fu

PE

6

8. Remove the water pump drain boltto drain the cooling system.Remove the cylinder drain bolts todrain the cooling system.After the coolant is completelydrained, thoroughly flush the cool-ing system with clean tap water.Install the water pump drain boltand cylinder drain bolts, and thentighten them to the specifiedtorques.

1. C2. R

ater pump drain boltylinder drain bolt (× 2)



6-15

Remove the right air intake duct byloosening the clamp screws.

9. Remove the radiator cap.EW000067

WARNING_

Never attempt to remove the radia-tor cap when the engine is hot. _

10. Place a container under the en-gine to collect the used coolant.

11.

12.

13.

14.

lamp screw (× 2)ight air intake duct

1. Radiator cap 1. W2. C

AND MINOR REPAIR

6

15

16

. Place the fuel tank in the originalposition, and then install the bolts.

. Install the cowlings.

. Install the seat.



6-16

. Install the coolant reservoir by in-stalling the bolts.

. Pour the specified amount of rec-ommended coolant into the radia-tor and reservoir.

ECA00041

CAUTION:_

Hard water or salt water is harmfulto the engine. You may use soft wa-ter if you can’t get distilled water. _

17. Install the radiator cap and thecoolant reservoir cap, start the en-gine, let it idle for several minutes,and then turn it off.

18. Remove the radiator cap to checkthe coolant level in the radiator. Ifnecessary, add sufficient coolantuntil it reaches the top of the radia-tor, and then install the radiatorcap.

19. Check the coolant level in the res-ervoir. If necessary, remove thecoolant reservoir cap, add coolantto the maximum level mark, andthen install the cap.

20. Start the engine, and then checkthe vehicle for coolant leakage. Ifcoolant is leaking, have a Yamahadealer check the cooling system.

21. Install the right air intake duct, andthen tighten the clamp screws.

22

2324

Tightening torques:Water pump drain bolt:

10 Nm (1.0 m·kgf)Cylinder drain bolt:

7.0 Nm (0.7 m·kgf)

Antifreeze/water mixture ratio:1:1

Recommended anti-freeze:High-quality ethylene glycol antifreeze containing corrosioninhibitors for aluminum engines

Coolant quantity:Total amount:

1.95 LCoolant reservoir capacity:

0.55 L

PE

6

ClTheat tmaClequewe

1.

2.3.

Pull the air filter element out.Clean the air filter element withsolvent, and then squeeze the re-maining solvent out.

1. F ir filter element



6-17

EAU04281*

eaning the air filter element air filter element should be cleaned

he intervals specified in the periodicintenance and lubrication chart.an the air filter element more fre-ntly if you are riding in unusually

t or dusty areas.Remove the seat. (See page 3-11for seat removal and installationprocedures.)Remove the fuel tank bolts.Lift the fuel tank to position it awayfrom the air filter case. (Do not dis-connect the fuel hoses!)

EW000071

WARNING_

� Make sure that the fuel tank iswell supported.

� Do not tilt or pull the fuel tanktoo much, otherwise the fuelhoses may come loose, whichcould cause fuel leakage.

_

4. Remove the air filter case cover byremoving the screws.

5.6.

uel tank bolt (× 2) 1. Air filter case cover2. Screw (× 8)

1. A

AND MINOR REPAIR

6

7

N_

Thno_

8

EAU00626

ecking the air vent hose riodically check the air vent hose forst or water that may be deposited in hose. If dust or water is found, re-ve the air vent hose, thoroughlyan it, and then install it.

EC000093

UTION: not operate the motorcycle with air vent hose removed.

ir vent hose



6-18

. Apply oil of the recommended typeto the entire surface of the spongematerial, and then squeeze the ex-cess oil out.

OTE:e air filter element should be wet butt dripping.

. Insert the air filter element into theair filter case.

EC000082*

CAUTION:_

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

� The engine should never be op-erated without the air filter ele-ment installed, otherwise thepistons and/or cylinders maybecome excessively worn.

_

9. Install the air filter case cover byinstalling the screws.

10. Place the fuel tank in the originalposition, and then install the bolts.

EW000072

WARNING_

� Before installing the fuel tank,make sure that the fuel hosesare not damaged. If any fuelhose is damaged, do not startthe engine but have a Yamahadealer replace the hose, other-wise fuel may leak.

� Make sure that the fuel hosesare properly connected androuted, and not pinched.

_

11. Install the seat.

ChPeduthemocle

CA_

Dothe_

Recommended oil:Engine oil

1. A

PE

6

AiChducnec

EAU00632

justing the engine idling eed engine idling speed must becked and, if necessary, adjusted asws at the intervals specified in the

iodic maintenance and lubricationrt.Start the engine and warm it up forseveral minutes at 1,000–2,000 r/min while occasionally rev-ving it to 4,000–5,000 r/min.

TE: engine is warm when it quickly re-nds to the throttle.

1. A



6-19

EAU01335

r intake duct eck that the screen of the intaket is not blocked. Clean the screen ifessary.

EAU00630

Adjusting the carburetors The carburetors are important parts ofthe engine and require very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described inthe following section, however, may beserviced by the owner as part of routinemaintenance.

EC000095

CAUTION:_

The carburetors have been set andextensively tested at the Yamahafactory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-mance of or damage to the engine. _

AdspThechefollopercha

1.

NO_

Thespo_

ir intake duct

AND MINOR REPAIR

6

2

N_

If obYa_

EAU00637

djusting the valve clearance e valve clearance changes with use,

sulting in improper air-fuel mixtured/or engine noise. To prevent thism occurring, the valve clearance

ust be adjusted by a Yamaha dealer the intervals specified in the periodicaintenance and lubrication chart.

1.



6-20

. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection a. To decrease the engineidling speed, turn the screw in di-rection b.

OTE:the specified idling speed cannot betained as described above, have amaha dealer make the adjustment.

EAU00635

Adjusting the throttle cable free play The throttle cable free play shouldmeasure 3–7 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, have aYamaha dealer adjust it.

AThreanfromatm

Throttle stop screw

Engine idling speed:1,200–1,300 r/min

a. Throttle cable free play

PE

6

TirTo ity,cycreg

TirThechebef

_

�

�

_

EWA00012

ARNINGse loading has an enormoust on the handling, braking,mance and safety characteris-f your motorcycle, you shouldthe following precautions in EVER OVERLOAD THEOTORCYCLE! Operation of anverloaded motorcycle may re-lt in tire damage, loss of con-

ol, or severe injury. Make sureat the total weight of rider,

assenger, cargo, and accesso-es does not exceed the speci-ed maximum load for thehicle.

o not carry along looselyacked items, which can shifturing a ride.



6-21

EAU00658

es maximize the performance, durabil- and safe operation of your motor-le, note the following pointsarding the specified tires.

e air pressure tire air pressure should becked and, if necessary, adjustedore each ride.

EW000082

WARNINGThe tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature). The tire air pressure must beadjusted in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor this model.

CE-01E

CE-07E

W_

Becauimpacperfortics okeep mind.

� NMosutrthprifive

� Dpd

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg225 kPa(2.25 kgf/cm2,2.25 bar)

250 kPa(2.50 kgf/cm2,2.50 bar)

90 kg–maximum250 kPa(2.50 kgf/cm2,2.50 bar)

290 kPa(2.90 kgf/cm2,2.90 bar)

High-speed riding250 kPa(2.50 kgf/cm2,2.50 bar)

290 kPa(2.90 kgf/cm2,2.90 bar)

Maximum load*180 kg (except for A, CH, S)178 kg (for A, CH, S)

* Total weight of rider, passenger, cargo and accessories

AND MINOR REPAIR

6

_

EW000079

WARNING� Have a Yamaha dealer replace

excessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases riding sta-bility and can lead to loss ofcontrol.

� The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.



6-22

� Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

� Adjust the suspension and tireair pressure with regard to theload.

� Check the tire condition and airpressure before each ride.

Tire inspectionThe tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nailor glass fragments in it, or if the side-wall is cracked, have a Yamaha dealerreplace the tire immediately.CE-08E

NOTE:_

The tire tread depth limits may differfrom country to country. Always complywith the local regulations. _

_

_

1. Tire sidewalla. Tire tread depth

Minimum tire tread depth (front and rear)

1.6 mm

PE

6

TirThiwh

E

E

1. T2. T3. T

NT

nufacturer Size Model

nlop120/60 ZR17 (55W)

D204F120/60 ZR17 M/C (55W)

tzeler120/60 ZR17 (55W)

MEZ1 FRONT120/60 ZR17 M/C (55W)

gestone120/60 ZR17 (55W)

BT57F120/60 ZR17 M/C (55W)

helin120/60 ZR17 (55W)

MACADAM 90X120/60 ZR17 M/C (55W)

R

nufacturer Size Model

nlop160/60 ZR17 (69W)

D204160/60 ZR17 M/C (69W)

tzeler160/60 ZR17 (69W)

MEZ1160/60 ZR17 M/C (69W)

gestone160/60 ZR17 (69W)

BT57160/60 ZR17 M/C (69W)

helin160/60 ZR17 (69W)

MACADAM 90X160/60 ZR17 M/C (69W)

FRONT & REAR

Tire air valve TR412

Valve core #9000A (original)



6-23

e informations motorcycle is equipped with casteels and tubeless tires with valves.

EW000080

WARNING_

� The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the motor-cycle cannot be guaranteed.

� After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

� Always make sure that the valvecaps are securely installed toprevent air pressure leakage.

� Use only the tire valves andvalve cores listed below toavoid tire deflation during ahigh-speed ride.

_

CE-10

CE-14

ire air valveire valve coreire valve cap with seal

FRO

Ma

Du

Me

Brid

Mic

REA

Ma

Du

Me

Brid

Mic

AND MINOR REPAIR

6

_

Thpelom

_



6-24

EAU00684

WARNINGis motorcycle is fitted with su-r-high-speed tires. Note the fol-wing points in order to make theost efficient use of these tires.� Use only the specified replace-

ment tires. Other tires may runthe danger of bursting at superhigh speeds.

� Brand-new tires can have a rela-tively poor grip on certain roadsurfaces until they have been“broken in”. Therefore, it is ad-visable before doing anyhigh-speed riding to ride con-servatively for approximately100 km after installing a newtire.

� The tires must be warmed upbefore a high-speed run.

� Always adjust the tire air pres-sure according to the operatingconditions.

EAU03773

Cast wheels To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels.

� The wheel rims should be checkedfor cracks, bends or warpage be-fore each ride. If any damage isfound, have a Yamaha dealer re-place the wheel. Do not attempteven the smallest repair to thewheel. A deformed or crackedwheel must be replaced.

� The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

� Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

PE

6

AdplaThesurchenec

1.

2.

3.

EAU00712

justing the brake pedal sition top of the brake pedal should beitioned approximately 42 mm below top of the footrest as shown. Peri-cally check the brake pedal position, if necessary, have a Yamahaler adjust it.

1. L2. Cc. C

istance between brake pedal and footrest



6-25

EAU00692

justing the clutch lever free y clutch lever free play should mea-

e 10–15 mm as shown. Periodicallyck the clutch lever free play and, ifessary, adjust it as follows.Loosen the locknut at the clutch le-ver.To increase the clutch lever freeplay, turn the adjusting bolt in di-rection a. To decrease the clutchlever free play, turn the adjustingbolt in direction b.Tighten the locknut.

NOTE:_

If the specified free play cannot be ob-tained as described above or if theclutch does not operate correctly, havea Yamaha dealer check the internalclutch mechanism. _

AdpoThepostheodianddea

ocknutlutch lever free play adjusting boltlutch lever free play

a. D

AND MINOR REPAIR

6

_

ApeaiisYafoththmac_



6-26

EW000109

WARNING soft or spongy feeling in the brakedal can indicate the presence of

r in the hydraulic system. If there air in the hydraulic system, have amaha dealer bleed the system be-re operating the motorcycle. Air ine hydraulic system will diminishe braking performance, whichay result in loss of control and ancident.

EAU00713

Adjusting the rear brake light switch The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction a. Tomake the brake light come on later,turn the adjusting nut in direction b.

1. Rear brake light switch2. Rear brake light switch adjusting nut

PE

6

ChbrThecheifielubproallowitbra

EAU03294

ecking the brake fluid level ufficient brake fluid may allow air toer the brake system, possibly caus- it to become ineffective.ore riding, check that the brake fluidbove the minimum level mark andlenish if necessary. A low brake flu-evel may indicate worn brake pads/or brake system leakage. If theke level is low, be sure to check theke pads for wear and the brake sys- for leakage.

1. B

Fr

inimum level mark

ont



6-27

EAU00715

ecking the front and rear ake pads front and rear brake pads must becked for wear at the intervals spec-

d in the periodic maintenance andrication chart. Each brake pad isvided with a wear indicator, whichws you to check the brake pad wear

hout having to disassemble theke.

To check the brake pad wear, checkthe position of the wear indicator whileapplying the brake. If a brake pad hasworn to the point that the wear indicatoralmost touches the brake disc, have aYamaha dealer replace the brake padsas a set.

ChInsentingBefis arepid landbrabratem

rake pad wear indicator (× 2)

ont

1. Brake pad wear indicator (× 2)

Rear

1. M

Fr

AND MINOR REPAIR

6

O

EAU03976

hanging the brake fluid ve a Yamaha dealer change the

ake fluid at the intervals specified ine NOTE after the periodic mainte-nce and lubrication chart. In addition,ve the oil seals of the master cylin-rs and calipers as well as the brakeses replaced at the intervals listedlow or whenever they are damaged leaking.� Oil seals: Replace every two

years.� Brake hoses: Replace every four

years.

1.

R



6-28

bserve these precautions:� When checking the fluid level,

make sure that the top of the brakefluid reservoir is level.

� Use only the recommended quali-ty brake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

� Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

� Be careful that water does not en-ter the brake fluid reservoir whenrefilling. Water will significantlylower the boiling point of the fluidand may result in vapor lock.

� Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

� As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

CHabrthnahadehobeor

Minimum level mark

Recommended brake fluid: DOT 4

ear

PE

6

DrThecheif n

To1.

NO_

Whchaposbe _

EAU03752

adjust the drive chain slack Loosen the axle nut, then loosenthe locknut at each end of theswingarm.To tighten the drive chain, turn theadjusting nut at each end of theswingarm in direction a. To loos-en the drive chain, turn the adjust-ing nut at each end of theswingarm in direction b, and thenpush the rear wheel forward.

xle nutlignment marksrive chain slack adjusting nutocknut



6-29

EAU00744

ive chain slack drive chain slack should becked before each ride and adjusted

ecessary.

check the drive chain slack Place the motorcycle on a levelsurface and hold it in an uprightposition.

TE:en checking and adjusting the drivein slack, the motorcycle should beitioned straight up and there shouldno weight on it.

2. Shift the transmission into the neu-tral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain, andthen measure the drive chainslack as shown.

4. If the drive chain slack is incorrect,adjust it as follows.

To 1.

2.

a. Drive chain slack

Drive chain slack:20–30 mm

1. A2. A3. D4. L

AND MINOR REPAIR

6

N_

Usibosi_

C_

Imlopatoprthsp_

3

ECA00052

AUTION: not use engine oil or any other

bricants for the drive chain, asey may contain substances thatuld damage the O-rings.



6-30

OTE:sing the alignment marks on eachde of the swingarm, make sure thatth adjusting nuts are in the same po-

tion for proper wheel alignment.

EC000096

AUTION:proper drive chain slack will over-

ad the engine as well as other vitalrts of the motorcycle and can lead chain slippage or breakage. Toevent this from occurring, keepe drive chain slack within theecified limits.

. Tighten the locknuts, and thentighten the axle nut to the specifiedtorque.

EAU03006

Lubricating the drive chain The drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

EC000097

CAUTION:_

The drive chain must be lubricatedafter washing the motorcycle orriding in the rain. _

1. Clean the drive chain with kero-sene and a small soft brush.

ECA00053

CAUTION:_

To prevent damaging the O-rings,do not clean the drive chain withsteam cleaners, high-pressurewashers or inappropriate solvents. _

2. Wipe the drive chain dry.3. Thoroughly lubricate the drive

chain with a special O-ring chainlubricant.

C_

Doluthco_

Tightening torque:Axle nut:

117 Nm (11.7 m·kgf)

PE

6

ChcaThethechebleed or Ya

_

Daterandrussoocon_

EAU03370

ecking and lubricating the ke and shift pedals operation of the brake and shiftals should be checked before each, and the pedal pivots should be lu-ated if necessary.

R

ecommended lubricant:Lithium-soap-based grease (all-purpose grease)



6-31

EAU02962

ecking and lubricating the bles operation of all control cables and

condition of the cables should becked before each ride, and the ca-

s and cable ends should be lubricat-if necessary. If a cable is damageddoes not move smoothly, have amaha dealer check or replace it.

EW000112

WARNINGmage to the outer sheath may in-fere with proper cable operation will cause the inner cable tot. Replace a damaged cable asn as possible to prevent unsafeditions.

EAU04034

Checking and lubricating the throttle grip and cable The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated orreplaced at the intervals specified inthe periodic maintenance chart.

ChbraThepedridebric

ecommended lubricant:Engine oil

R

AND MINOR REPAIR

6

CbThleridbr

EAU04282

bricating the rear spension e pivoting points of the rear suspen-n must be lubricated at the intervalsecified in the periodic maintenanced lubrication chart.

Recommended lubricant:Lithium-soap-based grease



6-32

EAU03164

hecking and lubricating the rake and clutch levers e operation of the brake and clutch

vers should be checked before eache, and the lever pivots should be lu-icated if necessary.

EAU03165

Checking and lubricating the sidestand The operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

EW000113

WARNING_

If the sidestand does not move upand down smoothly, have a Yamahadealer check or repair it. _

LusuThsiospan

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

PE

6

ChTheforkinteten

To

_

Sethaove_

Chdam

EAU00794

ecking the steering rn or loose steering bearings mayse danger. Therefore, the operationhe steering must be checked as fol-s at the intervals specified in the pe-ic maintenance and lubricationrt.Place a stand under the engine toraise the front wheel off theground.

EW000115

WARNINGurely support the motorcycle so

t there is no danger of it fallingr.



6-33

EAU02939

ecking the front fork condition and operation of the front must be checked as follows at thervals specified in the periodic main-ance and lubrication chart.

check the conditionEW000115

WARNINGcurely support the motorcycle sot there is no danger of it fallingr.

eck the inner tubes for scratches,age and excessive oil leakage.

To check the operation1. Place the motorcycle on a level

surface and hold it in an uprightposition.

2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses and re-bounds smoothly.

EC000098

CAUTION:_

If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-pair it. _

ChWocauof tlowriodcha

1.

_

Secthaove_

AND MINOR REPAIR

6

2



6-34

. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steer-ing.

EAU01144

Checking the wheel bearings The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealercheck the wheel bearings.

PE

6

BaThiseanotno add

CA_

Necelly d_

_

�

store the batteryIf the motorcycle will not be usedfor more than one month, removethe battery, fully charge it, andthen place it in a cool, dry place.If the battery will be stored formore than two months, check it atleast once a month and fullycharge it if necessary.Fully charge the battery before in-stallation.After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.



6-35

EAU00800

ttery s motorcycle is equipped with aled-type (MF) battery, which does require any maintenance. There isneed to check the electrolyte or to distilled water.

EC000101

UTION:ver attempt to remove the batteryl seals, as this would permanent-amage the battery.

EW000116

WARNINGElectrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.

• INTERNAL: Drink large quan-tities of water or milk and im-mediately call a physician.

• EYES: Flush with water for15 minutes and seek promptmedical attention.

� Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

� KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

_

To charge the batteryHave a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the motorcycle is equipped with op-tional electrical accessories.

To 1.

2.

3.

4.

AND MINOR REPAIR

6

C_

_

EC000103

AUTION: not use a fuse of a higher amper-e rating than recommended tooid causing extensive damage toe electrical system and possibly ae.

Main fuse

Specified fuses:Main fuse: 30 AHeadlight fuse: 20 ASignaling system fuse: 15 ARadiator fan fuse: 7.5 AIgnition fuse: 7.5 A



6-36

EC000102

AUTION:� Always keep the battery

charged. Storing a dischargedbattery can cause permanentbattery damage.

� To charge a sealed-type (MF)battery, a special (constant-volt-age) battery charger is required.Using a conventional batterycharger will damage the battery.If you do not have access to asealed-type (MF) battery charg-er, have a Yamaha dealer chargeyour battery.

EAU04246*

Replacing the fuses The main fuse and the fuse box, whichcontains the fuses for the individual cir-cuits, are located under the seat. (Seepage 3-11 for seat removal and instal-lation procedures.)If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn offthe electrical circuit in question.

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

C_

Doagavthfir_

1. Headlight fuse2. Signaling system fuse3. Ignition fuse4. Radiator fan fuse5. Spare fuse (× 2)

1.

PE

6

3.

4.

Unhook the headlight bulb holder,and then remove the defectivebulb.

eadlight bulb holder



6-37

Turn the key to “ON” and turn onthe electrical circuit in question tocheck if the device operates.If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU04160

Replacing the headlight bulb This motorcycle is equipped with aquartz bulb headlight. If the headlightbulb burns out, replace it as follows.

1. Disconnect the headlight coupler,and then remove the bulb cover.

2.

1. Headlight coupler2. Headlight bulb cover

1. H

ND MINOR REPAIR

6

_

Hfofrtodo_

3

EAU01623

placing the tail/brake light b Remove the tail/brake light lens byremoving the screws.Remove the defective bulb bypushing it in and turning it counter-clockwise.Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.Install the lens by installing thescrews.

EC000108

UTION:not overtighten the screws, oth-ise the lens may break.

1. crew (× 2)



6-38

EW000119

WARNINGeadlight bulbs get very hot. There-re, keep flammable products awayom a lit headlight bulb, and do notuch the bulb until it has cooledwn.

. Place a new headlight bulb intoposition, and then secure it withthe bulb holder.

EC000104

CAUTION:_

Take care not to damage the follow-ing parts:

� Headlight bulbDo not touch the glass part ofthe headlight bulb to keep it freefrom oil, otherwise the transpar-ency of the glass, the luminosi-ty of the bulb, and the bulb lifewill be adversely affected. Thor-oughly clean off any dirt and fin-gerprints on the headlight bulbusing a cloth moistened with al-cohol or thinner.

� Headlight lens• Do not affix any type of tinted

film or stickers to the head-light lens.

• Do not use a headlight bulb ofa wattage higher than speci-fied.

_

4. Install the headlight bulb cover,and then connect the coupler.

5. Have a Yamaha dealer adjust theheadlight beam if necessary.

Rebul

1.

2.

3.

4.

CA_

Do erw_

Do not touch this area. 1. S

PE

6

Rebu

1.

2.

3.

4.

CA_

Dowis_

rvice the rear wheel the rear wheel off the ground bya motorcycle stand or, if a motor-stand is not available, by placing either under each side of the

in front of the rear wheel or underside of the swingarm.

1. S



6-39

EAU03497

placing a turn signal light lb

Remove the turn signal light lensby removing the screw.Remove the defective bulb bypushing it in and turning it counter-clockwise.Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.Install the lens by installing thescrew.

ECA00065

UTION: not overtighten the screw, other-e the lens may break.

EAU01579

Supporting the motorcycle Since this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other mainte-nance requiring the motorcycle tostand upright. Check that the motor-cycle is in a stable and level positionbefore starting any maintenance. Astrong wooden box can be placed un-der the engine for added stability.

To service the front wheel1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To seRaiseusing cycle a jackframeeach

crew

AND MINOR REPAIR

6F

To

_

_

1

Remove the brake calipers oneach side by removing the bolts.Pull the wheel axle out, removethe speedometer gear unit, andthen remove the wheel.

ECA00046

UTION: not apply the brake after theke calipers have been removed,erwise the brake pads will beced shut.

1.2.3.4.5.6.

L



6-40

EAU03582

ront wheel

remove the front wheel EW000122

WARNING� It is advisable to have a Yamaha

dealer service the wheel.� Securely support the motor-

cycle so that there is no dangerof it falling over.

. Disconnect the speedometer ca-ble from the front wheel.

2. Remove the front fender by re-moving the bolts.

3. Loosen the front wheel axle pinchbolt, then the wheel axle and thebrake caliper bolts.

4. Lift the front wheel off the groundaccording to the procedure onpage 6-39.

5. Remove the brake hose holderson each side by removing thebolts.

6.

7.

CA_

Dobraothfor_

Speedometer cableBolt (× 2)Front fenderBolt (× 2)Brake caliperBrake hose holder

eft side

1. Front fender2. Bolt (× 2)3 Front wheel axle pinch bolt4. Wheel axle5. Bolt (× 2)6. Brake caliper7. Brake hose holder

Right side

PE

6

To1.

2.

NO_

Maetethe_

3.4.

EAU04197

wheel

ove the rear wheel EW000122

ARNINGis advisable to have a Yamahaaler service the wheel.curely support the motor-cle so that there is no danger it falling over.

1. S2. S3. S

nutheel axle guideut

chain slack adjusting nutl axle



6-41

EAU04196

install the front wheel Install the speedometer gear unitinto the wheel hub so that the pro-jections mesh with the slots.Lift the wheel up between the forklegs.

TE:ke sure that the slot in the speedom-r gear unit fits over the retainer on fork leg.

Insert the wheel axle.Lower the front wheel so that it ison the ground.

5. Install the brake calipers by install-ing the bolts.

NOTE:_

Make sure that there is enough spacebetween the brake pads before install-ing the brake calipers onto the brakediscs. _

6. Tighten the wheel axle, then thefront wheel axle pinch bolt and thebrake caliper bolts to the specifiedtorques.

7. Install the brake hose holders byinstalling the bolts.

8. Connect the speedometer cable.9. Install the front fender by installing

the bolts.10. Push down hard on the handlebar

several times to check for properfork operation.

Rear

To rem

W_

� It de

� Secyof

_

peedometer gear unitlotpeedometer gear unit retainer

Tightening torques:Wheel axle:

65 Nm (6.5 m·kgf)Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf)Brake caliper bolt:

40 Nm (4.0 m·kgf)

1. Axle 2. Left w3. Lockn4. Drive5. Whee

ND MINOR REPAIR

6

1

2

ull the wheel axle out along withhe right wheel axle guide, removehe brake caliper bracket, and thenemove the wheel.

ECA00048

TION:ot apply the brake after thel has been removed togetherthe brake disc, otherwise the

e pads will be forced shut.

1.2.3.4.

ke caliper bracket



6-42

. Loosen the wheel axle nut, thebrake torque rod nut at the brakecaliper bracket, and the brake cal-iper bolts.

. Lift the rear wheel off the groundaccording to the procedure onpage 6-39.

3. Remove the axle nut and the leftwheel axle guide, and then re-move the brake caliper by remov-ing the bolts.

4. Disconnect the brake torque rodfrom the brake caliper bracket byremoving the cotter pin, the nut,and the bolt.

5. Loosen the locknut and the drivechain slack adjusting nut on bothsides of the swingarm.

6. Push the wheel forward, and thenremove the drive chain from therear sprocket.

NOTE:_

The drive chain does not need to bedisassembled in order to remove andinstall the wheel. _

7. Pttr

CAU_

Do nwheewith brak_

Cotter pinNutBoltBrake torque rod

1. Bolt (× 2)2. Right wheel axle guide

1. Bra

PE

6

To1.

2.

3.

NO_

Mabetthe_

EAU03087

bleshooting gh Yamaha motorcycles receiveough inspection before shipmenthe factory, trouble may occur dur-eration. Any problem in the fuel,

ression, or ignition systems, forple, can cause poor starting andf power.ollowing troubleshooting chartsent quick and easy proceduresecking these vital systems your-owever, should your motorcycle

e any repair, take it to a Yamahar, whose skilled technicians haveecessary tools, experience, andhow to service the motorcyclerly.only genuine Yamaha replace-parts. Imitation parts may lookamaha parts, but they are oftenr, have a shorter service life andad to expensive repair bills.



6-43

EAU04283

install the rear wheel Install the wheel, right wheel axleguide, and caliper bracket by in-serting the wheel axle from theright-hand side.Install the drive chain onto the rearsprocket, and then install the leftwheel axle guide and the axle nut.Install the brake caliper by install-ing the bolts, and then connect thebrake torque rod to the brake cali-per bracket by installing the boltand nut.

TE:ke sure that there is enough spaceween the brake pads before installing brake caliper onto the brake disc.

4. Adjust the drive chain slack. (Seepage 6-29 for drive chain slack ad-justment procedures.)

5. Lower the rear wheel so that it ison the ground.

6. Tighten the axle nut, the brake cal-iper bolts and the brake torque rodnut to the specified torques.

7. Install a new cotter pin into thebrake torque rod bolt.

EWA00051

WARNING_

Always use a new cotter pin for thebrake torque rod bolt. _

TrouAlthoua thorfrom ting opcompexamloss oThe frepresfor chself. Hrequirdealethe nknow-propeUse ment like Yinferiocan le

Tightening torques:Axle nut:

117 Nm (11.7 m·kgf)Brake caliper bolt:

40 Nm (4.0 m·kgf)Brake torque rod nut:

30 Nm (3.0 m·kgf)

AND MINOR REPAIR

6

EAU02990

TroubleshootinStarting problems

EW000125

WARNING_

Keep away open fl ystem. _

1. Fue

s not start. pression.

The engine does not start.Have a Yamaha dealercheck the vehicle.

e engine does not start.eck the battery.

en the throttle halfway and operate electric starter.


Check the fuel lethe fuel tank.

Operate the elec

2. Compre

Remove the spaand check the el

3. Ignition

Operate the elec

4. Battery


6-44

g charts or poor engine performance

ames and do not smoke while checking or working on the fuel s

vel in

lThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine doeCheck the com

tric starter.

ssionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

rk plugsectrodes.

Wipe off with a dry cloth and correct thespark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

tric starter.

The engine turns over quickly.

The engine turns over slowly.

Dry

Wet

ThCh

Opthe

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

PE

6

EnEW000070

_

� ding hot fluid and steam may be until the engine has cooled.

� l, over the radiator cap, and thenessure to escape. When the hiss-wise, and then remove the cap.

_

NO_

If c anged to the recommended coolantas _

Have a Yamaha dealer checkand repair the cooling system.

Add coolant. (See NOTE.)

f the engine overheats again, have a eck and repair the cooling system.

ise.

is age.



6-45

gine overheating

WARNINGDo not remove the radiator cap when the engine and radiator are hot. Scalblown out under pressure, which could cause serious injury. Be sure to waitAfter removing the radiator cap retaining bolt, place a thick rag, like a toweslowly rotate the cap counterclockwise to the detent to allow any residual pring sound has stopped, press down on the cap while turning it counterclock

TE:oolant is not available, tap water can be temporarily used instead, provided that it is chsoon as possible.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is OK.

The coolant level is low.Check the cooling systemfor leakage.

Start the engine. IYamaha dealer ch

There leakag

There no leak

MOTORCYCLE CARE AND STORAGE

7

Care .................................................................................................. 7-1Storage .............................................................................................. 7-4


7

EAU03426

aningECA00010

UTION:


7-MO

CaWhreve

Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply acorrosion protection spray.Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

noloble.eveusenotifrommodoethe moand

7-1

TORCYCLE CARE AND STORAGE

re ile the open design of a motorcycleals the attractiveness of the tech-gy, it also makes it more vulnera- Rust and corrosion can developn if high-quality components ared. A rusty exhaust pipe may go un-ced on a car, however, it detracts the overall appearance of a

torcycle. Frequent and proper cares not only comply with the terms ofwarranty, but it will also keep your

torcycle looking good, extend its life optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug caps, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

Cle

CA_

�

�

ARE AND STORAGE

7

ter riding in the rain, near the sea or salt-sprayed roadsnce sea salt or salt sprayed on roadsring winter are extremely corrosive inmbination with water, carry out thellowing steps after each ride in thein, near the sea or on salt-sprayedads.

TE:lt sprayed on roads in the winter may

main well into spring.

. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.

ECA00012

AUTION: not use warm water since it in-

eases the corrosive action of thelt.

. Apply a corrosion protection sprayon all metal, including chrome-and nickel-plated, surfaces to pre-vent corrosion.


MOTORCYCLE C

7-2

� Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

� Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments, switch-es and lights), breather hosesand vents.

� For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaningcompounds for plastic mayleave scratches on the wind-shield. Test the product on asmall hidden part of the wind-shield to make sure that it doesnot leave any marks. If the wind-shield is scratched, use a quali-ty plastic polishing compoundafter washing.

_

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

AfonSiducoforaro

NO_

Sare_

1

C_

Docrsa_

2

M

7

Aft1.

2.

3.

4.

5.

6.

7.8.

TE:sult a Yamaha dealer for advice ont products to use.


OTORCYCLE CARE AND STORAGE

7-3

er cleaningDry the motorcycle with a chamoisor an absorbing cloth.Immediately dry the drive chainand lubricate it to prevent it fromrusting.Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.Use spray oil as a universal clean-er to remove any remaining dirt.Touch up minor paint damagecaused by stones, etc.Wax all painted surfaces.Let the motorcycle dry completelybefore storing or covering it.

EWA00001

WARNING_

� Make sure that there is no oil orwax on the brakes or tires. Ifnecessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent.

� Before operating the motor-cycle test its braking perfor-mance and cornering behavior.

_

ECA00013

CAUTION:_

� Apply spray oil and wax spar-ingly and make sure to wipe offany excess.

� Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

� Avoid using abrasive polishingcompounds as they will wearaway the paint.

_

NO_

Conwha_

ARE AND STORAGE

7

S

ShAldrag

C_

_

a. Remove the spark plug caps andspark plugs.

b. Pour a teaspoonful of engine oilinto each spark plug bore.

c. Install the spark plug caps onto thespark plugs, and then place thespark plugs on the cylinder headso that the electrodes are ground-ed. (This will limit sparking duringthe next step.)

d. Turn the engine over several timeswith the starter. (This will coat thecylinder walls with oil.)

e. Remove the spark plug caps fromthe spark plugs, and then installthe spark plugs and the spark plugcaps.

EWA00003

WARNING prevent damage or injury fromarking, make sure to ground theark plug electrodes while turninge engine over.


MOTORCYCLE C

7-4

torage

ort-termways store your motorcycle in a cool,y place and, if necessary, protect itainst dust with a porous cover.

ECA00014

AUTION:� Storing the motorcycle in a

poorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

� To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float chamberby loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into thefuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps to pro-tect the cylinders, piston rings, etc.from corrosion.

_

Tospspth_

M

7

6.

7.

8.

9.


OTORCYCLE CARE AND STORAGE

7-5

Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the sidestand/centerstand.Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C or more than 30 °C. Formore information on storing thebattery, see page 6-35.

NOTE:_

Make any necessary repairs beforestoring the motorcycle. _

SPECIFICATIONS

8

Specifications .................................................................................... 8-1Conversion table ............................................................................... 8-5


8

EAU01038


8-SP

SpCS-01

M

oil API Service SE, SF, SG or higher

ridge 2.6 L

e 2.9 L

gine) 3.5 L

-20 -10 0 10 20 30 40 50 ˚C

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

otor oils that do not contain anti-fric-ssenger car motor oils (often labeledRVING II”) contain anti-friction addi-

ause clutch and/or starter clutch slip- reduced component life and poor

ce.

D

Bf

E

8-1

ECIFICATIONS

ecifications E

odel YZF600R

imensions

Overall length 2,145 mm (except for F, E, I, GR)

2,060 mm (for F, E, I, GR)

Overall width 725 mm

Overall height 1,190 mm

Seat height 805 mm

Wheelbase 1,415 mm

Ground clearance 135 mm

Minimum turning radius 3,200 mm

asic weight (with oil and full uel tank) 212 kg (except for A, CH, S)

214 kg (for A, CH, S)

ngine

Engine type Liquid-cooled 4-stroke, DOHC

Cylinder arrangement Forward-inclined parallel4-cylinder

Displacement 599 cm3

Bore × stroke 62.0 × 49.6 mm

Compression ratio 12:1

Starting system Electric starter

Lubrication system Wet sump

Engine oil

Type

Recommended engine classification

Quantity

Without oil filter cartreplacement

With oil filter cartridgreplacement

Total amount (dry en

CAUTION:

Be sure to use mtion modifiers. Pa“ENERGY CONSEtives which will cpage, resulting inengine performan

SPECIFICATIONS

8

1st 2.846

2nd 1.947

3rd 1.545

4th 1.333

5th 1.190

6th 1.074

Diamond

25°

97 mm

Tubeless tire

120/60 ZR17 (55W)

120/60 ZR17 M/C (55W)

el Bridgestone / BT57F

Dunlop / D204F

Metzeler / MEZ1 FRONT

Michelin / MACADAM 90X


8-2

Cooling system capacity (total amount) 1.95 L

Air filter Wet element

Fuel

Type REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity 19 L

Reserve amount 3.1 L

Carburetor

Manufacturer KEIHIN

Model × quantity CVKD36 × 4

Spark plug

Manufacturer/model NGK / CR9E or DENSO / U27ESR-N

Gap 0.7–0.8 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 1.708

Secondary reduction system Chain drive

Secondary reduction ratio 3.133

Number of drive chain sprocket teeth (front/rear) 15/47

Transmission type Constant-mesh 6-speed

Operation Left foot

Gear ratio

Chassis

Frame type

Caster angle

Trail

Tires

Front

Type

Size

Manufacturer/mod

SP

8

Cast wheel

17 × MT 3.50

17 M/C × MT 3.50

Cast wheel

17 × MT 5.00

17 M/C × MT 5.00

Dual disc brake

Right hand

DOT 4

Single disc brake

Right foot

DOT 4

Telescopic fork

Swingarm (link suspention)

Coil spring / oil damper

Coil spring / gas-oil damper


ECIFICATIONS

8-3

Rear

Type Tubeless tire

Size 160/60 ZR17 (69W)

160/60 ZR17 M/C (69W)

Manufacturer/model Bridgestone / BT57

Dunlop / D204

Metzeler / MEZ1

Michelin / MACADAM 90X

Maximum load* 180 kg (except for A, CH, S)

178 kg (for A, CH, S)

Tire air pressure (measured on cold tires)

Up to 90 kg*

Front 225 kPa (2.25 kgf/cm2, 2.25 bar)

Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)

90 kg–maximum*



High-speed riding



* Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type

Size

Rear

Type

Size

Brakes

Front

Type

Operation

Fluid

Rear

Type

Operation

Fluid

Suspension

Front

Rear

Spring/shock absorber

Front

Rear

SPECIFICATIONS

8

30 A

20 A

15 A

7.5 A

7.5 A


8-4

Wheel travel

Front 130 mm

Rear 120 mm

Electrical system

Ignition system T.C.I. (digital)

Charging system

Type A.C. magneto

Standard output 14 V, 18.5 A @ 5,000 r/min

Battery

Model YTX12-BS

Voltage, capacity 12 V, 10 Ah

Headlight type Quartz bulb (halogen)

Bulb voltage, wattage × quantity

Headlight 12 V, 60/55 W × 1

Tail/brake light 12 V, 5/21 W × 1

Turn signal light 12 V, 21 W × 4

Auxiliary light 12 V, 4 W × 1

Meter lighting 12 V, 1.7 W × 4

Neutral indicator light 12 V, 3.4 W × 1

High beam indicator light 12 V, 3.4 W × 1

Oil level warning light 12 V, 3.4 W × 1

Turn signal indicator light 12 V, 3.4 W × 1

Fuel level warning light 12 V, 3.4 W × 1

Fuses

Main fuse

Headlight fuse

Signaling system fuse

Radiator fan fuse

Ignition fuse

SP

8

CoCS-0

AlME

Usun

Ex

M

nversion tableTEM TO IMPERIAL SYSTEM

nit Conversion factor Imperial unit

× 7.233× 86.794× 0.0723× 0.8679

ft·lbin·lbft·lbin·lb

× 2.205× 0.03527

lboz

× 0.6214 mi/h

× 0.6214× 3.281× 1.094× 0.3937× 0.03937

miftydinin

× 0.03527× 0.06102× 0.8799× 0.2199

oz (IMP liq.)cu·inqt (IMP liq.)gal (IMP liq.)

× 55.997× 14.2234× 1.8 + 32

lb/inpsi (lb/in2)°F


ECIFICATIONS

8-5

EAU03941

nversion table 3E

l specification data in this manual are listed in SI andTRIC UNITS.

e this table to convert METRIC unit values to IMPERIALit values.

ample:

ETRIC VALUE CONVERSION FACTOR

IMPERIAL VALUE

2 mm × 0.03937 = 0.08 in

CoMETRIC SYS

Metric u

Torque

m·kgfm·kgfcm·kgfcm·kgf

Weight kgg

Speed km/h

Distance

kmmmcmmm

Volume,Capacity

cc (cm3)cc (cm3)L (liter)L (liter)

Miscellaneouskgf/mmkgf/cm2

°C

CONSUMER INFORMATION

9

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


9

EAU01039


9-CO

IdeRec

EAU01043

hicle identification number vehicle identification number is

mped into the steering head pipe.ord this number in the space pro-d.

TE: vehicle identification number isd to identify your motorcycle andy be used to register your motor-le with the licensing authority inr area.

ehicle identification number

vehel lavideorddeacle

1.CA-02

2.

CA-02

3.CA-01

9-1

NSUMER INFORMATIONEAU02944

ntification numbers ord the key identification number,icle identification number and mod-bel information in the spaces pro-d below for assistance when

ering spare parts from a Yamahaler or for reference in case the vehi-is stolen.

KEY IDENTIFICATION NUMBER:E

VEHICLE IDENTIFICATIONNUMBER:

E

MODEL LABEL INFORMATION:E

EAU01041

Key identification number The key identification number isstamped into the key tag. Record thisnumber in the space provided and useit for reference when ordering a newkey.

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1. Key identification number 1. V

MER INFORMATION

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9-2

EAU01050

odel label e model label is affixed to the frameder the seat. (See page 3-11 for seatmoval and installation procedures.)ecord the information on this label ine space provided. This informationill be needed when ordering sparerts from a Yamaha dealer.

Model label

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dentification numbers ..............................9-1dling speed, adjusting ...........................6-19gnition circuit cut-off system ..................3-19ndicator and warning lights......................3-2

ey identification number .........................9-1

ight switch ..............................................3-6uggage strap holders ...........................3-18

ain switch/steering lock .........................3-1odel label ..............................................9-2

eutral indicator light ...............................3-2

il level warning light ...............................3-2

arking.....................................................5-6art locations ...........................................2-1ass switch..............................................3-5eriodic maintenance and lubrication chart ......................................................6-2re-operation check list............................4-1

afety information ....................................1-1eat .......................................................3-11elf-diagnosis device ...............................3-4


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e light switch (rear), adjusting .........6-26e pads, checking.............................6-27e pedal..............................................3-8e pedal position, adjusting ..............6-25

les, checking and lubricating............6-31uretors, adjusting............................6-19.........................................................7-1

ch lever..............................................3-7ch lever free play, adjusting .............6-25version table......................................8-5lant ..................................................6-13hanging..........................................6-14hecking ..........................................6-13

lant temperature gauge .....................3-5lings, removing and installing ............6-5

Fuel ......................................................... 3-9Fuel consumption, tips for reducing ......... 5-4Fuel level warning light ............................ 3-3Fuel tank breather hose

(Germany only) ................................... 3-10Fuel tank cap........................................... 3-8Fuses, replacing .................................... 6-36

HHandlebar switches ................................. 3-5Headlight bulb, replacing ....................... 6-37Helmet holder ........................................ 3-12High beam indicator light ......................... 3-3Horn switch ............................................. 3-6

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ilter element, cleaning......................6-17take duct ........................................6-19ent hose, checking..........................6-18theft alarm ........................................3-5

ery ...................................................6-35e and clutch levers, checking and ricating ............................................6-32e and shift pedals, checking and ricating ............................................6-31e fluid, changing .............................6-28e fluid level, checking......................6-27e lever...............................................3-7

DDimmer switch......................................... 3-5Drive chain, lubricating .......................... 6-30Drive chain slack ................................... 6-29

Adjusting .......................................... 6-29Checking.......................................... 6-29

EEngine break-in ....................................... 5-5Engine oil and oil filter cartridge ............. 6-10Engine stop switch................................... 3-6

FFront and rear suspension settings........ 3-17Front fork, adjusting............................... 3-13Front fork, checking ............................... 6-33

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INDEX

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rage.................................................... 7-4rage compartment ............................ 3-12pporting the motorcycle ..................... 6-39spension (rear), lubricating ................ 6-32

chometer ............................................. 3-4il/brake light bulb, replacing ............... 6-38rottle cable free play, adjusting .......... 6-20rottle grip and cable, checking and bricating............................................ 6-31es ...................................................... 6-21ol kit..................................................... 6-1ubleshooting..................................... 6-43ubleshooting charts .......................... 6-44

rn signal indicator light ......................... 3-3rn signal light bulb, replacing ............. 6-39rn signal switch.................................... 3-6

ifting .................................................... 5-3ift pedal ............................................... 3-7ift points (for Switzerland only)............. 5-4ock absorber assembly, adjusting ..... 3-15estand .............................................. 3-18estand, checking and lubricating....... 6-32ark plugs, checking ............................. 6-8ecifications .......................................... 8-1eedometer unit .................................... 3-3rter (choke) lever .............................. 3-11rting a warm engine............................ 5-3rting the engine .................................. 5-1rt switch.............................................. 3-6ering, checking ................................. 6-33

VValve clearance, adjusting .................... 6-20Vehicle identification number................... 9-1

WWheel bearings, checking ..................... 6-34Wheel (front) ......................................... 6-40

Installing.............................................6-41Removing ........................................ 6-40

Wheel (rear) .......................................... 6-41Installing .......................................... 6-43Removing ........................................ 6-41

Wheels.................................................. 6-24

Shiro.fm Page 1 Thursday, June 7, 2001 11:38 AM

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