Page 5 of 72
EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY .................1-1
DESCRIPTION ...................................................2-1
Left view .............................................................2-1
Right view...........................................................2-2
Controls and instruments ...................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ....3-1
Main switch/steering lock ..................................3-1
Indicator lights ...................................................3-2
Speedometer unit ..............................................3-2
Fuel gauge ........................................................3-2
Handlebar switches ...........................................3-3
Front brake lever ...............................................3-4
Rear brake lever ................................................3-4
Fuel tank cap .....................................................3-4
Fuel ...................................................................3-5
Starter (choke) lever ..........................................3-6
Kickstarter .........................................................3-6
Seat ...................................................................3-6
Helmet box ........................................................3-7
Convenience hook .............................................3-8
PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list .....................................4-1OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine .............5-1
Starting a warm engine .....................................5-2
Starting off .........................................................5-2
Acceleration and deceleration ...........................5-3
Braking ..............................................................5-3
Engine break-in .................................................5-4
Parking ..............................................................5-5
General note ......................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Owner’s tool kit ..................................................6-1
Periodic maintenance and lubrication chart ......6-2
Removing and installing the cowling and
panels ............................................................6-4
Checking the spark plug ....................................6-7
Engine oil and oil strainer ..................................6-9
Final transmission oil .......................................6-11
Cleaning the air filter element, V-belt case
air filter elements, and check hoses ............6-13
Adjusting the carburetor ..................................6-16
Adjusting the engine idling speed ...................6-17
Adjusting the throttle cable free play ...............6-17
Adjusting the valve clearance .........................6-18
1234
56
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Page 9 of 72
DESCRIPTION
2-2
2
Right view7. Engine oil filler cap (page 6-9)
8. Air filter element (page 6-13)
9. Battery (page 6-29)
10. Fuses (page 6-31)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
Periodic maintenance and lubrication chart
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×1,000 km)
0.5 2 4 8 12
1*Fuel line
Check fuel hoses and vacuum hose for cracks or damage.√√√√
2 Spark plugCheck condition.
Clean and regap.√√√√√
Replace if necessary.√√√
3*ValvesCheck valve clearance.
Adjust.√√√√√
4 Air filter element
Clean. Replace if necessary.√√√√
5V-belt case air filter
elementsClean. Replace if necessary.√√√√
6*BatteryCheck electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-3.)
Replace brake pads if necessary.√√√√√
8*Rear brakeCheck operation and adjust brake lever free play.
Replace brake shoes if necessary.√√√√√
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
10*Wheel bearings
Check bearing for looseness or damage.√√√√
11*SwingarmCheck operation and for excessive play.
Lubricate with lithium-soap based grease, every 24,000 km.√√√√
12*Steering bearingsCheck bearing play and steering for roughness.
Lubricate with lithium-soap-based grease, every 12,000 km.√√√√√
13*Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.√√√√
14 Sidestand/centerstandCheck operation.
Lubricate.√√√√
15*Front fork
Check operation and for oil leakage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU03057*
NOTE:_
From 16,000 km, repeat the maintenance intervals starting from 4,000 km.
Depending on riding conditions, the V-belt replacement interval may vary.
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake system
After disassembling the brake master cylinder, and caliper cylinder, always change the fluid. Regularly check the
brake fluid level and fill reservoir as required.
Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years.
Replace the brake hose every four years or if cracked or damaged.
_16
*Shock absorber
assembliesCheck operation and shock absorbers for oil leakage.√√√√
17*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√
18 Engine oilChange.
Check oil level and vehicle for oil leakage.√√Every 2,000 km
19*Engine oil strainer
Clean.√√
20 Final transmission oilCheck vehicle for oil leakage.√√√√√
Change.√Every 10,000 km
21*V-beltCheck the damage and wear.√√√
Replace. Every 25,000 km (See NOTE.)
22*Front and rear brake
switchesCheck operation.√√√√√
23 Moving parts and cables
Lubricate.√√√√
24*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×1,000 km)
0.5 2 4 8 12
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAUM0058*
Cleaning the air filter element,
V-belt case air filter elements,
and check hoses The air filter and the V-belt case air fil-
ter elements should be cleaned at the
intervals specified in the periodic main-
tenance and lubrication chart. Clean
both filter elements more frequently if
you are riding in unusually wet or dusty
areas. In addition, the air filter check
hoses must be frequently checked and
cleaned if necessary.
Cleaning the air filter element
1. Place the motorcycle on the cen-
terstand.
2. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)3. Remove the air filter case cover by
removing the screws.4. Pull the air filter element out.
1. Air filter case cover
2. Screw (× 5)
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 5. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air.
6. Check the air filter element for
damage and replace it if neces-
sary.
7. Insert the air filter element into the
air filter case.
8. Install the air filter case cover by
installing the screws.
9. Install the panel.Cleaning the V-belt case air filter
elements
1. Remove V-belt case air filter cover
A by removing the bolts.2. Remove V-belt case air filter cover
B by removing the bolts.
1. V-belt case air filter cover A
2. Bolt (× 2)
1. V-belt case air filter cover B
2. Bolt (× 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
63. Remove the air filter elements,
and then blow out the dirt with
compressed air as shown.4. Check each air filter element for
damage and replace them if nec-
essary.
5. Install the air filter elements.
6. Install V-belt case air filter cover B
by installing the bolts.7. Install V-belt case air filter cover A
by installing the bolts.
EC000092*
CAUTION:_
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston and/or cylinder may be-
come excessively worn.
_
1. Air filter element (× 2)U5MXE0.book Page 15 Thursday, December 20, 2001 2:08 PM
Page 43 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 To clean the air filter check hoses
1. Check each hose at the bottom of
the air filter case and the V-belt
case for accumulated dirt or water.2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU00629
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000094
CAUTION:_ The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. _
1. Check hose (× 2)
1. Check hose
U5MXE0.book Page 16 Thursday, December 20, 2001 2:08 PM
