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6
EC000099
CAUTION:@ When inspecting the battery, be
sure the breather hose is routed cor-
rectly. If the breather hose is posi-
tioned in such a way as to cause
battery electrolyte or gas to exit
onto the frame, structural and cos-
metic damage to the motorcycle can
occur. @
EW000116
WARNING
@ Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:l
EXTERNAL: Flush with water.
l
INTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
l
EYES: Flush with water for
15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
@
Replenishing the battery fluid
A poorly maintained battery will cor-
rode and discharge quickly. The bat-
tery fluid should be checked at least
once a month. The level should be be-
tween the minimum level and maxi-
mum level marks. Use only distilled
water if refilling is necessary.
EC000100
CAUTION:@ Normal tap water contains minerals
which are harmful to a battery;
therefore, refill only with distilled
water. @
EW000117
WARNING
@ Take care not to spill battery fluid on
the chain. Battery fluid may weaken
the chain causing shorter chain life
and possibly result in an accident. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6Battery storage
l
When the motorcycle will not be
used for a month or longer, re-
move the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.
l
If the battery will be stored for
longer than two months, check the
specific gravity of the fluid at least
once a month and fully recharge
the battery when it is too low.
l
Always make sure the connec-
tions are correct when putting the
battery back in the motorcycle.
Make sure the breather hose is
properly connected and is not
damaged or obstructed.
EAU01307
Fuse replacementThe fuse is located behind panel B.
(See page 6-5 for panel removal and
installation procedures.) If the fuse is
blown, turn off the main switch and the
switch of the circuit in question. Install a
new fuse of proper amperage. Turn on
the switches and see if the electrical
device operates. If the fuse immediate-
ly blows again, consult a Yamaha deal-
er.
EC000103
CAUTION:@ Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire. @
1. Fuse box
Specified fuse: 20 A
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6
EAU03003
Headlight bulb replacementThis motorcycle is equipped with a
quartz bulb headlight.
If the headlight bulb burns out, replace
the bulb as follows:
1. Remove the headlight unit screws.
2. Remove the connector, the head-
light unit and then the bulb holder
cover.3. Turn the bulb holder counterclock-
wise to remove it and remove the
defective bulb.
EWA00023
WARNING
@ Keep flammable products and your
hands away from the bulb while it is
on, as it is hot. Do not touch the bulb
until it cools down. @4. Put a new bulb into position and
secure it in place with the bulb
holder.
ECA00040
CAUTION:@ Avoid touching the glass part of the
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on the bulb, thoroughly clean it with
a cloth moistened with alcohol or
lacquer thinner. @5. Install the bulb holder cover, con-
nector and headlight unit.
Ask a Yamaha dealer to adjust the
headlight beam if that adjustment
is necessary.
1. Screw (´ 2)
2. Bulb holder cover
1. Bulb holder
1. Don’t touch
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6
EAU00855*
Turn signal and tail/brake light
bulb replacement1. Remove the screws and the lens.
2. Push the bulb inward and turn it
counterclockwise.3. Place a new bulb in the socket.
Push the bulb inward and turn it
clockwise until it engages into the
socket.
4. Install the lens and the screws.
EC000108
CAUTION:@ Do not over-tighten the screws as
the lens may break. @
EAU00866
Front wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Remove the speedometer cable
from the front wheel side.
1. Screw (´ 2)
1. Screw
1. Speedometer cable
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6 3. Loosen the pinch bolt.
4. Remove the wheel axle. Make
sure the motorcycle is properly
supported.
NOTE:@ Do not depress the brake lever when
the disc and caliper are separated. @
EAU01394
Front wheel installation1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the pro-
jections meshed into the slots.
2. Lift up the wheel between the front
fork legs and guide the brake disc
between the brake pads. Make
sure the slot in the speedometer
gear unit fits over the stopper on
the front fork outer tube.
3. Install the wheel axle and let the
motorcycle down.4. Push down hard on the handle-
bars several times to check for
proper fork operation.
5. Tighten the wheel axle to the
specified torque.
6. Install the pinch bolt and tighten it
to the specified torque.
7. Install the speedometer cable.
1. Wheel axle
2. Pinch bolt
Tightening torque:
Wheel axle:
59 Nm (5.9 m·kg)
Pinch bolt:
20 Nm (2.0 m·kg)
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6
EAU01116*
Rear wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Place the motorcycle on the cen-
terstand.
2. Remove the cotter pin and nut.
Then remove the brake torque rod
bolt from the brake shoe plate.
3. Remove the brake adjusting nut
and brake rod from the brake cam
lever.4. Loosen the chain adjusting plates
on each side.
5. Remove the axle nut.
6. Pull out the rear axle.
7. Push the wheel forward and re-
move the drive chain.
8. Remove the wheel assembly.
1. Adjusting nut
2. Brake rod
3. Brake torque rod
4. Cotter pin
1. Axle nut
2. Chain adjusting plate
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6
EAU01723*
Rear wheel installation1. Install the rear wheel and the axle.
2. Install the axle nut and let the
motorcycle down.
3. Insert the brake rod into the brake
cam lever and install the brake
pedal free play adjusting nut.
4. Install the brake torque rod bolt
and tighten to the specified tight-
ening torque. Then install a new
cotter pin.
5. Adjust the drive chain free play.
(See page 6-22.)
6. Tighten the axle nut to the speci-
fied tightening torque.7. Adjust the rear brake pedal height
and free play. (See page 6-17.)
EW000103
WARNING
@ Check the operation of the brake
light after adjusting the rear brake. @
EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills. Specified torque:
Brake torque rod bolt:
25 Nm (2.5 m·kg)
Specified torque:
Axle nut:
65 Nm (6.5 m·kg)
E_3mw.book Page 33 Monday, February 5, 2001 9:54 AM
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6
EAU03009
Troubleshooting chart
EW000125
WARNING
@ Never check the fuel system while smoking or in the vicinity of an open flame. @
Check if there is fuel in
the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark plug and
check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plug.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check fluid, recharge,
check connections.
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