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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EW000099*
WARNING
_ A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
EAU00704*
Adjusting the rear brake lever
free play The rear brake lever free play should
measure 10–20 mm as shown. Period-
ically check the rear brake lever free
play and, if necessary, adjust it as fol-
lows.To increase the rear brake lever free
play, turn the adjusting nut at the brake
shoe plate in direction a. To decrease
the rear brake lever free play, turn the
adjusting nut in direction b.
EW000101
WARNING
_ If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment. _
a. Rear brake lever free play
1. Rear brake lever free play adjusting nut
U5MXE0.book Page 22 Thursday, December 20, 2001 2:08 PM
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6-23
6
EAU00720
Checking the front brake pads
and rear brake shoes The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU04502
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
1. Brake pad wear indicator groove (× 3)Front
1. Brake shoe wear indicator
2. Brake shoe wear limit lineRear
U5MXE0.book Page 23 Thursday, December 20, 2001 2:08 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00732
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:
When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
NOTE:_ If DOT 4 is not available, DOT 3 can be
used. _
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
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.
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
Recommended brake fluid: DOT 4
U5MXE0.book Page 24 Thursday, December 20, 2001 2:08 PM
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6-25
6
EAU03985
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
EAU00770*
Checking the V-belt The V-belt must be checked by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and lu-
brication chart.NOTE:_ It is recommended to replace the V-belt
every 25,000 km. _
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
_ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. _Recommended lubricant:
Engine oil
U5MXE0.book Page 25 Thursday, December 20, 2001 2:08 PM
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6
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03118
Lubricating the front and rear
brake levers The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5MXE0.book Page 26 Thursday, December 20, 2001 2:08 PM
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6
EAU03371
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EW000114
WARNING
_ If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5MXE0.book Page 27 Thursday, December 20, 2001 2:08 PM
Page 55 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
U5MXE0.book Page 28 Thursday, December 20, 2001 2:08 PM
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EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU03806*
Battery A poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)2. Unhook the battery band, and then
disconnect the negative battery
lead from the battery.
3. Pull the battery breather hose out
as shown.
4. Pull the battery out of the battery
compartment.
1. Negative battery lead
2. Battery band
3. Battery breather hose
U5MXE0.book Page 29 Thursday, December 20, 2001 2:08 PM
