Page 48 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
10*WheelsCheck runout and for damage.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
15*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assembliesCheck operation and shock absorbers for oil leakage.√√√√
21*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
E_5ea.book Page 3 Tuesday, October 2, 2001 3:54 PM
Page 49 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU04408
NOTE:_
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake and clutch service
Regularly check and, if necessary, correct the brake and clutch fluid levels.
Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master
and release cylinders, and change the brake and clutch fluids.
Replace the brake and clutch hoses every four years and if cracked or damaged.
_23 Engine oil filter elementReplace.√√√
24
*Front and rear brake
switchesCheck operation.√√√√√ √
25 Moving parts and cablesLubricate.√√√√ √
26*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
E_5ea.book Page 4 Tuesday, October 2, 2001 3:54 PM
Page 61 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EW000079
WARNING
_
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
_
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.
After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
_CE-10E
CE-14E
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
FRONT
Manufacturer Size Model
Dunlop120/70 ZR17 (58W)
D220F ST M
120/70 ZR17 M/C (58W)
Michelin120/70 ZR17 (58W)
MACADAM90X E
120/70 ZR17 M/C (58W)
REAR
Manufacturer Size Model
Dunlop180/55 ZR17 (73W)
D220 ST M
180/55 ZR17 M/C (73W)
Michelin180/55 ZR17 (73W)
MACADAM90X E
180/55 ZR17 M/C (73W)FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
E_5ea.book Page 16 Tuesday, October 2, 2001 3:54 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00684
WARNING
_ This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient use of these tires.
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km after installing a new
tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the operating
conditions.
_
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00712
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 40 mm below
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.a. Distance between brake pedal and footrest
E_5ea.book Page 17 Tuesday, October 2, 2001 3:54 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal 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. _
EAU01756
Rear brake light switch
adjustment The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
1. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)2. Turn the adjusting nut while hold-
ing the rear brake light switch in
place. To make the brake light
come on earlier, turn the adjusting
nut in direction
a. To make the
brake light come on later, turn the
adjusting nut in direction
b.
3. Install the panel.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
E_5ea.book Page 18 Tuesday, October 2, 2001 3:54 PM
Page 64 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU01314
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator groove,
which allows you to check the brake
pad wear without having to disassem-
ble 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 groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU04169
Checking the brake and clutch
fluid levels Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos-
sibly causing them to become ineffec-
tive.
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.
1. Brake pad wear indicator grooveFront
1. Brake pad wear indicator grooveRear
1. Minimum level markFront brake
E_5ea.book Page 19 Tuesday, October 2, 2001 3:54 PM
Page 65 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
NOTE:_ The rear brake fluid reservoir is located
behind panel A. (See page 6-5 for panel
removal and installation procedures.) Observe these precautions:
When checking the fluid level,
make sure that the top of the brake
or clutch fluid reservoir is level.
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch per-
formance.
The brake or clutch fluid reservoir
diaphragm will lose its shape from
the negative pressure if the fluid
level goes down too far. Be sure to
return the diaphragm to its original
shape before installing it into the
brake or clutch fluid reservoir.
Be careful that water does not en-
ter the brake or clutch fluid reser-
voir when refilling. 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 and clutch
fluid: DOT 4 brake fluidRear brake
1. Minimum level markClutch
E_5ea.book Page 20 Tuesday, October 2, 2001 3:54 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU03984
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake and clutch hoses: Replace
every four years.
EAU00745
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on the cen-
terstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.
5. If the drive chain slack is incorrect,
adjust it as follows.
a. Drive chain slack
Drive chain slack:
20–30 mm
E_5ea.book Page 21 Tuesday, October 2, 2001 3:54 PM
