6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Cowling removal and installation .......................... 6-5
Cowling A.............................................................. 6-5
Cowling B.............................................................. 6-6
Spark plug inspection ........................................... 6-7
Engine oil .............................................................. 6-8
Final gear oil replacement .................................. 6-11
Air filter ............................................................... 6-11
Carburetor adjustment ........................................ 6-13
Idle speed adjustment ........................................ 6-13
Throttle cable free play inspection ...................... 6-14
Valve clearance adjustment ................................ 6-14
Tires .................................................................... 6-15
Wheels ................................................................ 6-18
Clutch lever free play adjustment........................ 6-18
Brake light switch adjustment ............................. 6-19
Checking the front and rear brake pads.............. 6-19
Inspecting the brake fluid level............................ 6-20Brake fluid replacement ..................................... 6-21
Cable inspection and lubrication ........................ 6-21
Throttle cable and grip lubrication ...................... 6-21
Brake and shift pedal lubrication ........................ 6-22
Brake and clutch lever lubrication ...................... 6-22
Center and sidestand lubrication ....................... 6-22
Front fork inspection ........................................... 6-23
Steering inspection ............................................ 6-23
Wheel bearings .................................................. 6-24
Battery................................................................ 6-24
Fuse replacement .............................................. 6-25
Headlight bulb replacement ............................... 6-26
Front wheel removal ........................................... 6-27
Front wheel installation ...................................... 6-29
Rear wheel removal ........................................... 6-30
Rear wheel installation ....................................... 6-31
Troubleshooting .................................................. 6-31
Troubleshooting chart ......................................... 6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU02938
Engine oilOil level inspection
1. Place the motorcycle on the cen-
terstand. Warm up the engine for
several minutes.NOTE:@ Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings. @
2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.NOTE:@ Wait a few minutes until the oil level
settles before checking. @3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill the en-
gine with sufficient oil to reach the
specified level.Engine oil and oil filter cartridge re-
placement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
1. Engine oil level window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU00733
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and replen-
ish when necessary.
Observe these precautions:l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
l
Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
NOTE:@ If DOT 4 is not available, DOT 3 can be
used for the front brake only. @
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
Have a Yamaha dealer check the
cause if the brake fluid level goes
down.
1. Minimum level mark
1. Minimum level markRecommended brake fluid: DOT 4
10-INDEXAAir filter .................................................. 6-11
Antitheft alarm (optional) ..........................3-7BBattery ................................................... 6-24
Brake and clutch lever lubrication........... 6-22
Brake and shift pedal lubrication ............ 6-22
Brake fluid replacement ......................... 6-21
Brake light switch adjustment ................. 6-19CCable inspection and lubrication ............ 6-21
Carburetor adjustment ........................... 6-13
Care.........................................................7-1
Center and sidestand lubrication ............ 6-22
Checking the front and
rear brake pads ................................... 6-19
Clutch lever ............................................ 3-10
Clutch lever free play adjustment ........... 6-18
Controls/Instruments ................................2-3
Cowling A ................................................6-5
Cowling B ................................................6-6
Cowling removal and installation ..............6-5DDiagnosis device......................................3-7
Digital clock..............................................3-8
Dimmer switch .........................................3-9EEngine break-in........................................5-5
Engine oil .................................................6-8
Engine stop switch ................................. 3-10
FFinal gear oil replacement ..................... 6-11
Front brake lever ................................... 3-11
Front fork adjustment............................. 3-16
Front fork inspection .............................. 6-23
Front wheel installation .......................... 6-29
Front wheel removal .............................. 6-27
Fuel ....................................................... 3-13
Fuel gauge .............................................. 3-8
Fuel indicator circuit check....................... 3-5
Fuel indicator light ................................... 3-3
Fuel tank breather hose
(for Germany only) .............................. 3-14
Fuel tank cap ......................................... 3-12
Fuse replacement.................................. 6-25GGive safety the right of way ..................... 1-1HHandlebar switches ................................. 3-9
Dimmer switch ................................... 3-9
Engine stop switch ........................... 3-10
Hazard switch .................................... 3-9
Horn switch ........................................ 3-9
Lights switch .................................... 3-10
Pass switch ........................................ 3-9
Start switch ...................................... 3-10
Turn signal switch .............................. 3-9
Hazard switch .......................................... 3-9
Headlight bulb replacement ................... 6-26
Helmet holder ........................................ 3-15
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-9
IIdentification number records ...................9-1
Idle speed adjustment ............................6-13
Indicator lights ..........................................3-3
Fuel indicator light...............................3-3
High beam indicator light ....................3-3
Neutral indicator light ..........................3-3
Oil level indicator light .........................3-3
Turn indicator lights ............................3-3
Inspecting the brake fluid level ...............6-20KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ..........................................3-10MMain switch/Steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-3OOil level indicator circuit check .................3-4
Oil level indicator light ..............................3-3PParking.....................................................5-6
Pass switch ..............................................3-9
Periodic maintenance and lubrication .......6-2
Pre-operation check list ............................4-1