Page 57 of 112
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.
_22 Engine oil filter cartridge
Replace.√√√
23
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change.Every 3 years
24 Final gear oilCheck oil level and vehicle for oil leakage.
Change.√√√√√
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cables
Lubricate.√√√√ √
27*Throttle grip housing and
cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Muffler and exhaust pipe
Check the screw clamp for looseness.√√√√√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×
1,000 km)
ANNUAL
CHECK
1 10203040
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Page 62 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU05018
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil
(with or without oil filter cartridge
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–6 if the oil filter cartridge is
not being replaced. _
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
2. Engine oil filter cartridge
3. Engine oil drain bolt
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Page 63 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 4. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.NOTE:_ Make sure that the O-ring is properly
seated. _
6. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.NOTE:_ Check the washer for damage and re-
place it if necessary. _
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
1. Oil filter cartridge
2. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
U5JWE2.book Page 10 Wednesday, November 6, 2002 3:32 PM
Page 64 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00133
CAUTION:_
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _10. Turn the engine off, and then
check the oil level and correct it if
necessary. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.8 L
With oil filter cartridge
replacement:
4 L
Total amount (dry engine):
4.9 L
U5JWE2.book Page 11 Wednesday, November 6, 2002 3:32 PM
Page 65 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU04067
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil must be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
EW000066
WARNING
_
Make sure that no foreign mate-
rial enters the final gear case.
Make sure that no oil gets on
the tire or wheel.
_
To check the final gear oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_
The final gear oil level must be
checked on a cold engine.
Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false read-
ing.
_2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:_ The oil level should be at the brim of
the filler hole. _3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
2. Remove the oil filler bolt and drain
bolt to drain the oil from the final
gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the specified
torque.
4. Add the recommended final gear
oil to the brim of the filler hole.
1. Final gear oil filler bolt
2. Final gear oil drain bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
U5JWE2.book Page 12 Wednesday, November 6, 2002 3:32 PM
Page 66 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
65. Install and tighten the filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU04861
Checking the coolant level The coolant level should be checked as
follows before each ride. In addition,
the coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the motorcycle on the cen-
terstand.NOTE:_
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
Recommended final gear oil:
Shaft drive gear oil
(Part No.: 9079E-SH001-00)
Oil quantity:
0.2 L
1. Maximum level mark
2. Minimum level mark
U5JWE2.book Page 13 Wednesday, November 6, 2002 3:32 PM
Page 77 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 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, and dirt may clog the ABS
hydraulic unit valves.
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 fluidClutch
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Page 78 of 112
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
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.
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. _
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.
Recommended lubricant:
Engine oil
U5JWE2.book Page 25 Wednesday, November 6, 2002 3:32 PM
