D Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. Page 69 S Adjust headlight beam. NOTE: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Front cowling assembly Back view mirror Meter unit Headlight unit For installation, reverse the removal procedure.
S When the valve clearance is to be measured or adjusted, the piston must be at top dead center TDC on the compression stroke. For each cylinder, starting with cylinder 1 at TDC, turn the crankshaft clockwise as speci- fied in the following table.
S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. Install the new valve pad 1 and the valve lift- er 2. S Lubricate the valve lifter with molybdenum dis- ulfide oil. S The valve lifter must turn smoothly when ro- tated by hand. Stand the motorcycle on a level surface.
NOTE: Place the motorcycle on a suitable stand. Adjust: S carburetor synchronization a. Synchronize carburetor 1 to carburetor 2 by turning the synchronizing screw 1 in ei- ther direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. Start the engine and let it warm up for several minutes. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained.
Engine idling speed is in- Direction creased. Engine idling speed is Direction decreased. Carburetor side a. Loosen the locknut 2 on the decelerator cable. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. Disconnect: S spark plug cap 2. Install: S spark plug 13 Nm 1. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range! Check the ignition system.
NOTE: The ignition timing is not adjustable. Measure: S compression pressure Above the maximum pressure! Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure! Squirt a few drops of oil into the affected cylinder and measure again. S Make sure that the motorcycle is upright. Let the engine idle for a few minutes. Start the engine, warm it up for several min- utes, and then turn it off. Place a container under the engine oil drain bolt.
Remove: S engine oil filler cap 1 S engine oil drain bolt 2 along with the gasket 4. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm 1. Check: S engine oil drain bolt gasket Damage!
Install: S engine oil drain bolt 43 Nm 4. Check: S clutch cable free play a Out of specification! Clutch cable free play at the end of the clutch lever 10 X 15 mm 2.
Remove: S seat S fuel tank S side cover S cover 1 2. Remove: S air filter case cover 1 S air filter element 3.
Clean: S air filter element Apply compressed air to the outer surface of the air filter element. S The arrow mark a on the fuel filter should face to the side of the fuel pump 1.
Remove: S seat S fuel tank 2. Disconnect the EXUP servomotor connector b. Connect the battery to the EXUP servomotor connector and check if the servomotor oper- ates properly.
Loosen both locknuts 1. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. S Use only distilled water.
Soft water may be used if distilled water is not available. Disconnect: S coolant reservoir hose 1 3. Drain: S coolant from the coolant reservoir 4. Check: S copper washer 1 S coolant drain bolt 2 Damage! Install: S coolant drain bolt 7 Nm 0. Connect: S coolant reservoir hose Fill: S cooling system with the specified amount of the recom- mended coolant Recommended antifreeze High-quality ethylene glycol anti If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant.
Adjust: S brake lever position distance a from the throttle grip to the brake lever a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. Check: S brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification!
Brake pedal position below the top of the rider footrest 40 mm 2. Operate the brake. Check: S front brake pad S rear brake pad Wear indicator groove 1 almost disap- peared! Replace the brake pads as a set. Check: S brake hose clamp 2 Loose connection! Bleed: S hydraulic brake system a. Add the recommended brake fluid to the proper level. Install the diaphragm brake master cylinder reservoir or brake fluid reservoir. Connect a clear plastic hose 1 tightly to the bleed screw 2. Adjust: S adjusting bolt length a.
Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction Shift pedal is raised. Adjust: S drive chain slack a. Loosen the brake caliper bracket bolt. Loosen the wheel axle nut 1. Loosen both locknuts 2. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is ob- tained. If the drive chain is not maintained proper- ly, it will wear out rapidly.
Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5. NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench Lower ring nut initial tightening Adjust: S spring preload a. Turn the adjusting bolt 1 in direction a or Spring preload is Direction increased suspension is harder. Spring preload is Direction decreased suspension is softer.
Adjust: S compression damping a. Turn the adjusting screw 1 in direction a or Compression damping is Direction increased suspension is harder. Turn the adjusting ring 1 in direction a or b. Align the desired position on the adjusting ring with the stopper 2. Spring preload is Direction Direction increased s spension is increased suspension is harder. Page No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.
Front tire Manufacturer Type Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. S Make sure that the battery vent is free of ob- structions. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Check: S battery vent Obstruction! Install: S battery 8. Replace: S blown fuse a. Turn off the ignition. Install a new fuse of the correct amperage rating. Turn on the switches to verify if the electrical circuit is operational.
Disconnect: S headlight coupler 1 S bulb cover 2 2. Remove: S headlight bulb holder 1 3. Adjust: S headlight beam vertically a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Direction Headlight beam is lowered. NOTE: discs Place the motorcycle on a suitable stand Oil seal left and right Wheel bearing left and right Spacer For assembly, reverse the disassembly procedure. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Check: S wheel axle Roll the wheel axle on a flat surface. Remove the wheel bearings 3 with a gener- al bearing puller. Install the new wheel bearings and oil seals in the reverse order of disassembly.
Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification! Brake disc thickness limit minimum 4.
Adjust: S brake disc deflection a. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: S wheel axle 1 72 Nm 7. Spin the front wheel. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Measure: S brake disc deflection Out of specification! Correct the brake disc deflection or replace the brake disc. Remove the brake disc. Rotate the brake disc by one bolt hole. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.
Brake pad clip Brake pad pin Brake pad spring brake pad Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw For installation, reverse the removal Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Remove: S brake pad clips 1 S brake pad pins 2 S brake pad spring 3 3. Remove: S brake pads 1 along with the brake pad shims 4.
Measure: S brake pad wear limit Out of specification! Install new brake pad shims onto the new brake pads. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation.
Brake pad wear limit 0. Check: S brake fluid level Below the minimum level mark a! Brake lever Brake switch lead Brake switch Union bolt Disconnect: S brake switch coupler from the brake switch 2.
S brake fluid delivery passages brake master cylinder body Obstruction! Blow out with compressed air. S Never use solvents on internal brake com- ponents. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Install: S copper washers 1 S brake hose 2 S union bolt 3 30 Nm 3. Brake fluid Drain. Union bolt Copper washer Brake hose The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system.
S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. S Never use solevents on internal brake com- ponents as they will cause the piston seals to swell and distort.
S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
Remove: S spacer 1 S spring seat 2 S spring 3 S damper adjusting rod 4 3. Drain: S fork oil 4. A damaged oil seal or bush- ing must be replaced. S Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. To de- Never attempt to turn an adjusting This shock absorber assembly is crease the spring preload and thereby mechanism beyond the maximum or equipped with a spring preload adjust Raise the sidestand or may explode due to excessive system.
Page 33 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. Keep the clutch lever pulled. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused for example, as a result of exposure to the elements.
Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Exhaust fumes Before Page 38 35 seconds with the starter does not go off after starting starting with sufficient fuel, choke turned on, then about 2. At the recommended shift points 3. Shift the transmission into the neu- EAU Engine break-in shown in the following table, close tral position when the motorcycle There is never a more important period the throttle, and at the same time, is almost completely stopped.
Page Parking Do not park on a slope or on soft the tachometer red zone. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. Consult a Yamaha dealer before at- tempting any changes. Refer to this section each time a panel needs to be removed and installed.
Spark plug cap problems yourself. Instead, have a 2. Remove the spark plug as shown, Yamaha dealer check the vehicle.
Check each spark plug for elec- 2. Clean the surface of the spark plug EAU Canister for California only trode erosion and excessive car- gasket and its mating surface, and bon or other deposits, and replace then wipe off any grime from the it if necessary.
The engine oil should be between the cartridge 3. Remove the engine oil filler cap minimum and maximum level marks. Page 54 Make sure that the O-ring is properly 17 Nm 1. Yamaha dealer. Install the engine oil drain bolt, and 6. Install the new oil filter cartridge then tighten it to the specified 5. Place the vehicle on the center- In order to prevent clutch slip- check the vehicle.
Page 56 If water has been added to the page Place a container under the engine reservoir cap, add coolant to the check the antifreeze content of to collect the used coolant. Page 57 If water has been added to the Recommended antifreeze: coolant, have a Yamaha dealer High-quality ethylene glycol anti- freeze containing corrosion inhibitors check the antifreeze content of for aluminum engines Start the engine, and then check Remove the fuel tank bolts.
Install the panels. Rubber cover 2. Rubber cover holder 1. Page 59 Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- 1.
Air filter case cover wise fuel may leak. Page Adjusting The Carburetors Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. Throttle cable free play The throttle cable free play should mea- sure 3. Page Adjusting The Valve Clearance Rear: from occurring, the valve clearance regarding the specified tires.
Page 62 minimum tread depth , if the tire has a nail or glass fragments in it, or if the sidewall is cracked, con- tact a Yamaha dealer immediately and have the tire replaced.
Minimum tire tread depth front and rear : 1. This motorcycle is fitted with super- Use only the tire valves and high-speed tires. Page Cast Wheels The accessories or replace- fore each ride. If any damage is ment parts you choose for your found, have a Yamaha dealer re- motorcycle should be designed spe- place the wheel. Do not attempt cifically for this model, and they Clutch lever free play adjusting bolt 1.
Distance between brake pedal and footrest 2. Clutch lever free play Front brake 1. Check: spark plug type Incorrect Change. Normal color is a medium-to-light tan color. Clean: spark plug with a spark plug cleaner or wire brush 6.
Measure: spark plug gap a with a wire gauge Out of specification. NOTE: Before installing the spark plug, clean the spark plug and gasket surface. Connect: spark plug cap. Make sure that all connections are tight and free of corrosion. Install: battery powered timing light 1 inductive self-powered tachometer 2 to the spark plug lead of cyl.
Check: ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range Check the ignition system. NOTE: The ignition timing is not adjustable.
NOTE: Insufficient compression pressure will result in a loss of performance. Measure: valve clearance Out of specification Adjust. Start the engine, warm it up for several minutes, and then turn it off. Disconnect: spark plug cap 4.
CAUTION: Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. Measure: compression pressure Above the maximum pressure Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits.
Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again. Refer to the following table. Compression pressure with oil applied into cylinder Reading Higher than without oil Diagnosis Piston ring -s wear or damage Repair. Piston, valves, cylinder head gasket or piston possibly defective Repair. Compression pressure at sea level. Compression pressure at sea level : Standard: 1, kPa Turn the main switch to ON. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright.
Check: engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b. Below the minimum level mark Add the recommended engine oil to the proper level.
Therefore, do not add any chemical additives. Do not allow foreign materials to enter the crankcase. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. Place a container under the engine oil drain bolt.
Remove: engine oil filler cap 1 engine oil drain bolt 2 along with the gasket 4. Drain: engine oil completely from the crankcase 5. If the oil filter cartridge is also to be replaced, perform the following procedure. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm 1. Check: engine oil drain bolt gasket Damage Replace. Install: engine oil drain bolt 43 Nm 4.
Fill: crankcase with the specified amount of the recommended engine oil Quantity Total amount 3. Install: engine oil filler cap Check: engine for engine oil leaks Check: engine oil pressure a.
Slightly loosen the oil gallery bolt 1. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Start the engine after solving the problem -s and check the engine oil pressure again.
Tighten the oil gallery bolt to specification. Check: S clutch cable free play a Out of specification! Clutch cable free play at the end of the clutch lever 10 X 15 mm 0. Adjust: S clutch cable free play Handlebar side a. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a Direction b Clutch cable free play is increased.
Clutch cable free play is decreased. Tighten the locknut. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side.
Engine side a. Clean: air filter element Apply compressed air to the outer surface of the air filter element. Check: air filter element Damage Replace. Install: air filter element air filter case cover. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating.
NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks. Install: cover side cover fuel tank seat EAS Remove: seat fuel tank air filter case panel 1. Install: air chamber cover fuel tank seat. Remove: seat fuel tank side cover. NOTE: Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
The arrow mark a on the fuel filter should face to the side of the fuel pump 1. Install: side cover fuel tank seat. Remove: seat fuel tank 2.
Loose connection Connect properly. Install: fuel tank seat EAS Check: tightening torque Exhaust pipe nut 4 20 Nm 2. Remove: S seat S fuel tank 2. S vent hose Obstruction! Install: S fuel tank S seat. Disconnect the EXUP servomotor connector 1. Connect the battery to the EXUP servomotor connector and check if the servomotor operates properly. Battery positive lead! Check that the EXUP valve operates properly. Connect the EXUP servomotor connector.
Check: EXUP cable free play a. Adjust: EXUP cable free play a. Loosen both locknuts 1. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable free play. Tighten both locknuts and then remove the pin. Check: coolant level The coolant level should be between the maximum level mark a and minimum level marks b.
Below the minimum level mark Add the recommended coolant to the proper level. Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. Use only distilled water. Soft water may be used if distilled water is not available. Disconnect: coolant reservoir hose 1 3. Drain: coolant from the coolant reservoir. Therefore, do not remove the radiator cap when the engine is hot.
Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap, while still pressing down turn it counterclockwise, and then remove it. The following procedure applies to all of the coolant drain bolts and copper washers.
Remove: coolant drain bolt 1 along with the copper washer 6. Drain: coolant from the engine and radiator. Check: copper washer 1 coolant drain bolt 2 Damage Replace. Install: coolant drain bolt. Connect: coolant reservoir hose If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.
S Use only distilled water. S If coolant comes into contact with painted surfaces, immediately wash them with water. S Do not mix different types of antifreeze. Install: S radiator cap. Fill: S coolant reservoir with the recommended coolant to the maximum level mark a Install: S coolant reservoir cap NOTE: Before checking the coolant level, wait a few minutes until it settles. S fuel tank S seat. Adjust: brake lever position distance a from the throttle grip to the brake lever a.
While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Distance a is the largest. Distance a is the smallest. WARNING After adjusting the brake lever position, make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial.
A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system. Check: brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification!
Brake pedal position below the top of the rider footrest 40 mm 1. Adjust: brake pedal position a. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Direction b Brake pedal is raised. Brake pedal is lowered. Tighten the locknut 1 to specification. Locknut 18 Nm 1. Check: brake fluid level Below the minimum level mark a! Add the recommended brake fluid to the proper level. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure that the top of the reservoir is horizontal. Operate the brake. Check: front brake pad rear brake pad Wear indicator groove 1 almost disappeared! Replace the brake pads as a set. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
Check: rear brake light operation timing Incorrect! Adjust: rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.
Direction a Direction b Brake light comes on sooner. Brake light comes on later. Check: brake hose clamp 2 Loose connection! Hold the motorcycle upright and apply the brake.
Check: brake hose 1 Activate the brake several times. Brake fluid leakage! Replace the damaged hose. WARNING Bleed the hydraulic brake system whenever: the system was disassembled, a brake hose was loosened or removed, the brake fluid level is very low, brake operation is faulty. Remove: reservoir cap 1 diaphragm 2 NOTE: Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.
Bleed: hydraulic brake system. Install the diaphragm brake master cylinder reservoir or brake fluid reservoir. Connect a clear plastic hose 1 tightly to the bleed screw 2. A Front B Rear d. Place the other end of the hose into a container.
Slowly apply the brake several times. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. Loosen the bleed screw. This will release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. Tighten the bleed screw and then release the brake lever or brake pedal.
Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose. Tighten the bleed screw to specification.
Bleed screw 6 Nm 0. Fill the reservoir to the proper level. Check: shift pedal position distance a from the top of the rider footrest to the top of the shift pedal Out of specification! Shift pedal position below the top of the rider footrest 40 mm 1. Adjust: adjusting bolt length. Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction a Direction b Shift pedal is raised.
Shift pedal is lowered. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.
NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Rotate the rear wheel several times and check the drive chain to locate its tightest point. Check: drive chain slack a Out of specification! Drive chain slack 40 X 50 mm 1. Loosen the brake caliper bracket bolt.
Loosen the wheel axle nut 1. Loosen both locknuts 2. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is obtained.
Drive chain is tightened. Drive chain is loosened. NOTE: To maintain the proper wheel alignment, adjust both sides evenly. Tighten both locknuts to specification. Locknut 16 Nm 1. Tighten the wheel axle nut to specification. Wheel axle nut Nm 15 m kg, ft lb. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
This motorcycle has a drive chain with small rubber O-rings between each side plate. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosine to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Check: steering head Grasp the bottom of the front fork legs and gently rock the front fork.
Looseness or binding! Adjust the steering head. Adjust: steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5.
NOTE: Set the torque wrench at a right angle to the spanner wrench. Spanner wrench YU Lower ring nut initial tightening torque 52 Nm 5. Loosen the lower ring nut 6 completely, then tighten it to specification. Lower ring nut final tightening torque 18 Nm 1.
Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and inspect the upper and lower bearings. Install the rubber washer 7. Install the upper ring nut 8. Finger tighten the upper ring nut 8 , then align the slots of both ring nuts.
If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.
Install the lock washer 9. NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b. Steering stem nut Nm 11 m kg, 80 ft lb Upper bracket pinch bolt 30 Nm 3. Hold the motorcycle upright and apply the front brake. Check: operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Unsmooth operation! Uneven adjustment can result in poor handling and loss of stability.
Securely support the motorcycle so that there is no danger of it falling over. Spring preload. Never go beyond the maximum or minimum adjustment positions.
Turn the adjusting bolt 1 in direction a or b. Direction a Spring preload is increased suspension is harder. Spring preload is decreased suspension is softer. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b.
Direction a Rebound damping p g is increased suspension is harder. Rebound damping p g is decreased suspension is softer. Adjust: compression damping a. Direction a Compression damping is increased suspension is harder. Compression damping is decreased suspension is softer. Adjust: spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owners tool kit. Turn the adjusting ring 1 in direction a or b.
Align the desired position on the adjusting ring with the stopper 2. Direction a Spring preload is s spension is increased suspension harder. Spring preload is spension decreased s suspension is softer. Adjust: rebound damping a. Turn the adjusting knob 1 in direction a or b. Direction a Rebound damping is s spension is increased suspension harder.
Rebound damping is s spension is decreased suspension softer. Measure: tire pressure Out of specification! The tire pressure and the suspension must be adjusted according to the total weight including cargo, rider, passenger and accessories and the anticipated riding speed. Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. When the tire tread reaches the wear limit, replace the tire immediately.
Replace the tire. Minimum tire tread depth 1. WARNING Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure that the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. A Tire B Wheel Tubeless wheel Tube or tubeless tire After extensive tests, the tires listed below have been approved by Yamaha Motor Co.
The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Therefore, approximately km 62 mi should be traveled at normal speed before any highspeed riding is done.
NOTE: For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in the direction of wheel rotation. Align the mark 2 with the valve installation point. Replace damaged cable sheaths and cables as soon as possible.
Check: cable sheath Damage! Check: cable operation Unsmooth operation! Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device. Recommended lubricant lithium soap base grease EAS Recommended lubricant lithium soap base grease. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries.
Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames e. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
EYES Flush with water for 15 minutes and get immediate medical attention. Internal Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil.
Get immediate medical attention. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. Charging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries.
The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery. NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. Remove: S seat 2. Disconnect: S battery leads from the battery terminals. Remove: S battery 4. Check: S battery charge a. Connect a pocket tester to the battery terminals. Tester positive lead! S No charging is necessary when the open-circuit voltage equals or exceeds Check the charge of the battery, as shown in the charts and the following example. Example c. S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to remove it from the motorcycle. If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.
S To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. S Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
S Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. S If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.
Hot batteries can explode! S As shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. Connect a charged and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. If the setting is lower, charging will be insufficient.
If too high, the battery will be over-charged. By turning the charging voltage adjust dial, set the charging voltage at 20 X 24 V. Adjust the voltage so that the current is at the standard charging level. YES Monitor the amperage for 3 X 5 minutes to check if the standard charging current is reached. Set the time according to the charging time suitable for the open-circuit voltage.
Refer to Battery condition checking steps. If the current does not exceed the standard charging current after 5 minutes, replace the battery. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours.
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