6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ..................................................... 6-1
Periodic maintenance and lubrication chart.......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge ........................... 6-8
Coolant .............................................................. 6-11
Cleaning the air filter element ............................ 6-15
Adjusting the carburetors ................................... 6-17
Adjusting the engine idling speed ...................... 6-17
Adjusting the throttle cable free play .................. 6-18
Adjusting the valve clearance ............................ 6-18
Tires .................................................................... 6-19
Wheels ................................................................ 6-22
Adjusting the clutch lever free play .................... 6-22
Adjusting the brake pedal position ..................... 6-23
Adjusting the rear brake light switch .................. 6-24
Checking the front and rear brake pads ............. 6-24
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26
Drive chain slack................................................. 6-27
Lubricating the drive chain ................................. 6-28Checking and lubricating the cables ................. 6-29
Checking and lubricating the throttle grip
and cable ........................................................ 6-29
Lubricating the brake pedal ............................... 6-30
Checking and lubricating the brake
and clutch levers ............................................. 6-30
Checking and lubricating the sidestand ............ 6-30
Lubricating the rear suspension ........................ 6-31
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-32
Checking the wheel bearings ............................ 6-32
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-34
Replacing the headlight bulb ............................. 6-35
Replacing the tail/brake light bulb ..................... 6-37
Replacing a turn signal light bulb ...................... 6-37
Supporting the motorcycle ................................ 6-38
Front wheel ........................................................ 6-39
Rear wheel ......................................................... 6-41
Troubleshooting .................................................. 6-42
Troubleshooting charts ....................................... 6-43
E_5jj_PeriodicTOC.fm Page 1 Wednesday, February 2, 2000 5:18 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EC000103
CAUTION:@ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. @3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU00826
Replacing the headlight bulb This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.2. Unhook the headlight bulb holder,
and then remove the defective
bulb.1. Coupler
2. Headlight bulb cover
1. Headlight bulb holder
E_5jj_Periodic.fm Page 35 Wednesday, February 2, 2000 5:18 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EW000119
WARNING
@ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. @3. Place a new bulb into position, and
then secure it with the bulb holder.
EC000104
CAUTION:@ Take care not to damage the follow-
ing parts:l
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosi-
ty of the bulb, and the bulb life
will be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.
l
Headlight lens
• Do not affix any type of tinted
film or stickers to the head-
light lens.
• Do not use a headlight bulb of
a wattage higher than speci-
fied.
@4. Install the bulb cover, and then
connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Don’t touch
E_5jj_Periodic.fm Page 36 Wednesday, February 2, 2000 5:18 PM
SPECIFICATIONS
8-3
8
Maximum load* 201 kg
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 250 kPa (2.50 kg/cm
2, 2.50 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
High-speed riding
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Ty p e C a s t
Size 17 ´ MT 3.50
Rear
Ty p e C a s t
Size 17 ´ MT 6.00
Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Fr o n t
Ty p e Te l e s c o p i c f o r k
Rear
Type Swingarm (link suspension)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 135 mm
Rear 130 mm
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 365 W@ 5,000 r/min
Battery
Model GT12B-4
Voltage, capacity 12 V, 10 Ah
Headlight typeQuartz bulb (halogen)
E_5jj_Spec.fm Page 3 Wednesday, February 2, 2000 5:19 PM
SPECIFICATIONS
8-4
8
Bulb voltage, wattage ´ quantity
Headlight 12 V, 60/55 W ´ 2
Tail/brake light 12 V, 5/21 W ´ 2
Turn signal light 12 V, 21 W ´ 4
Auxiliary light 12 V, 5 W ´ 2
Neutral indicator light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Oil level warning light LED
Fuses
Main fuse 30 A
Headlight fuse 20 A
Signaling system fuse 20 A
Radiator fan fuse 10 A
Ignition fuse 15 A
Odometer fuse 10 A
E_5jj_Spec.fm Page 4 Wednesday, February 2, 2000 5:19 PM
10-INDEXAAir filter element, cleaning ...................... 6-15
Anti-theft alarm (optional) .........................3-8BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-30
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever............................................. 3-11
Brake pedal............................................ 3-11
Brake pedal, lubricating.......................... 6-30
Brake pedal position, adjusting .............. 6-23CCables, checking and lubricating............ 6-29
Carburetors, adjusting............................ 6-17
Care.........................................................7-1
Clutch lever ............................................ 3-10
Clutch lever free play, adjusting ............. 6-22
Controls and instruments .........................2-3
Conversion table ......................................8-5
Coolant .................................................. 6-11
Changing .......................................... 6-13
Checking .......................................... 6-11
Cowlings and panels, removing and
installing ................................................6-5DDrive chain, lubricating ........................... 6-28
Drive chain slack .................................... 6-27
Adjusting .......................................... 6-27
Checking .......................................... 6-27
EEngine break-in ....................................... 5-4
Engine idling speed ............................... 6-17
Engine oil and oil filter cartridge ............... 6-8
Engine, starting a cold ............................. 5-1
Engine, starting a warm ........................... 5-3
EXUP system ........................................ 3-22FFront and rear brake pads, checking ..... 6-24
Front and rear suspension settings ........ 3-21
Front fork, adjusting ............................... 3-16
Front fork, checking ............................... 6-31
Front wheel ........................................... 6-39
Installing........................................... 6-40
Removing......................................... 6-39
Fuel ....................................................... 3-12
Fuel consumption, tips for reducing ......... 5-4
Fuel tank breather hose ......................... 3-13
Fuel tank cap ......................................... 3-11
Fuses, replacing .................................... 6-34HHandlebar switches ................................. 3-9
Dimmer switch ................................... 3-9
Engine stop switch ............................. 3-9
Horn switch ........................................ 3-9
Light switch ........................................ 3-9
Pass switch ........................................ 3-9
Start switch ...................................... 3-10
Turn signal switch .............................. 3-9
Headlight bulb, replacing ....................... 6-35
Helmet holders ...................................... 3-15
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-23
Indicator lights ..........................................3-2
Coolant temperature warning light ......3-3
Fuel level warning light .......................3-2
High beam indicator light ....................3-2
Neutral indicator light ..........................3-2
Oil level warning light ..........................3-3
Turn signal indicator light ....................3-2KKey identification number .........................9-1LLeft view...................................................2-1
Luggage strap holders ...........................3-22MMain switch/steering lock .........................3-1
Model label ..............................................9-2
Motorcycle, supporting ...........................6-38OOwner’s tool kit ........................................6-1PParking.....................................................5-5
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1
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