Page 37 of 102
PRE-OPERATION CHECKS
4-2
4
NOTE:_ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. _
EWA00033
WARNING
_ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. _Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-21,6-23
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-14-6-17
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-24
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-24
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-25
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-16 ITEM CHECKS PAGE
E_5ea.book Page 2 Tuesday, October 2, 2001 3:54 PM
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 77 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU04412
Front wheel To remove the front wheel
EW000122
WARNING
_
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.2. Remove the brake hose holders
by removing the bolts.
3. Remove the brake calipers by re-
moving the bolts.
ECA00047
CAUTION:_ Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. _
4. Loosen the front wheel axle pinch
bolt, then the wheel axle.
5. Place the motorcycle on the cen-
terstand.
6. Pull the wheel axle out, and then
remove the wheel.
1. Speedometer cable
1. Bolt (× 3)
2. Brake hose holder
3. Front brake caliperLeft
Right
1. Front wheel axle pinch bolt
2. Wheel axle
E_5ea.book Page 32 Tuesday, October 2, 2001 3:54 PM
Page 78 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU04360
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.2. Lift the wheel up between the fork
legs.
NOTE:_ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. _3. Insert the wheel axle.
4. Install the brake calipers by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _
5. Install the brake hose holders by
installing the bolts.
6. Take the motorcycle off the cen-
terstand so that the front wheel is
on the ground.
7. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
8. Connect the speedometer cable.
9. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Speedometer gear unit retainer
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
E_5ea.book Page 33 Tuesday, October 2, 2001 3:54 PM
Page 79 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EAU04413
Rear wheel To remove the rear wheel
EW000122
WARNING
_
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
caliper bolts.2. Disconnect the brake torque rod
from the brake caliper bracket by
removing the nut and the bolt.
3. Place the motorcycle on the cen-
terstand.4. Remove the axle nut and the
brake caliper by removing the
bolts.
ECA00082
CAUTION:_ Do not apply the brake after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut. _5. Loosen the locknuts, and then turn
the drive chain slack adjusting bolt
on each side of the swingarm fully
in direction
a.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
1. Locknut
2. Drive chain slack adjusting bolt
3. Axle nut
1. Bolt
2. Brake torque rod
3. Nut
4. Brake caliper bracket
5. Brake caliper
6. Bolt (× 2)
1. Wheel axle
E_5ea.book Page 34 Tuesday, October 2, 2001 3:54 PM
Page 80 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _7. While supporting the wheel and
the brake caliper bracket, pull the
wheel axle out.
8. Remove the brake caliper bracket
and the wheel.
EAU03895
To install the rear wheel
1. Place the wheel and the brake cal-
iper bracket in the original position.
2. Insert the wheel axle through the
brake caliper bracket and wheel
from the right-hand side, and then
install the axle nut.
3. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-22 for
drive chain slack adjustment pro-
cedures.)
4. Connect the brake torque rod to
the brake caliper bracket by in-
stalling the bolt and the nut.
5. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. _6. Take the motorcycle off the cen-
terstand so that the rear wheel is
on the ground.7. Tighten the axle nut, brake caliper
bolts and brake torque rod nut to
the specified torques.
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Brake torque rod nut:
23 Nm (2.3 m·kgf)
E_5ea.book Page 35 Tuesday, October 2, 2001 3:54 PM
