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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03884
NOTE:_
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
•Replace the brake hoses every four years and if cracked or damaged.
_25
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change. Every 3 years
26*Front and rear brake
switches•Check operation.√√√√√ √
27 Moving parts and cables•Lubricate.√√√√ √
28*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5MTE1.book Page 5 Monday, August 6, 2001 6:10 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
CE-08ENOTE:@ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. @
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.
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU01357
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 7–11 mm be-
low the bottom of the footrest bracket
as shown. Periodically check the brake
pedal position and, if necessary, have
a Yamaha dealer adjust it.
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. _
EAU00713
Adjusting the rear brake light
switch 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.
Turn the adjusting nut while holding 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.
a. Distance between brake pedal and footrest
bracket
1. Rear brake light switch
2. Rear brake light switch adjusting nut
U5MTE1.book Page 26 Monday, August 6, 2001 6:10 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU00721
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.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. 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.
EAU01641
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the rear brake caliper by
removing the bolt, and then tilt the
caliper forward to inspect the wear
indicator groove. If a brake pad
has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer re-
place the brake pads as a set.
1. Brake pad wear indicator grooveFront
1. Bolt
2. Rear brake caliperRear
U5MTE1.book Page 27 Monday, August 6, 2001 6:10 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 2. Install the brake caliper by install-
ing the bolt, then tightening it to the
specified torque.
EAU03294
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 brake
fluid reservoir is level.
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
1. Brake pad wear indicator groove
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)Rear
1. Minimum level markFront
1. Minimum level markRecommended brake fluid: DOT 4Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
Be careful that water does not en-
ter the brake fluid reservoir 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.
EAU03976
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 master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU00744
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 a level
surface and hold it in an upright
position.NOTE:@ When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it. @2. Shift the transmission into the neu-
tral position.
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6-32
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.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03163
Lubricating the brake pedal The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5MTE1.book Page 32 Monday, August 6, 2001 6:10 PM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
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
steering.
U5MTE1.book Page 34 Monday, August 6, 2001 6:10 PM
