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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Place the spark plug cover in the
original position.
EAU04618
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.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.
a. Spark plug gapSpark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
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.
_
6. 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. _7. Turn the engine off, and then
check the oil level and correct it if
necessary.NOTE:_ Have a Yamaha dealer replace the oil
filter element when necessary. _
EAU04083
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 level must be
checked and the oil 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.
_
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
3.0 L
Total amount (dry engine):
3.6 L
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Page 59 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To check the final gear oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:_
The final gear oil level must be
checked on a cold engine.
Make sure that the motorcycle is
positioned straight up when check-
ing the oil level. A slight tilt to the
side can result in a false reading.
_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.
NOTE:_ GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used. _5. Install and tighten the oil filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended final gear oil:
Hypoid gear oil SAE 80
(API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.2 L
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Page 60 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EAU03195*
Cleaning the air filter element The air filter element should be cleaned
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.4. Insert the air filter element into the
air filter case as shown.
EC000082*
CAUTION:@
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@5. Install the air filter case cover by
installing the screws.
1. Air filter case cover
2. Screw (× 3)
1. Air filter element
2. Projection
3. Slot
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU01746
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 98.5 mm
above the top of the footrest as shown.
Periodically check the brake pedal po-
sition 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
1. Rear brake light switch
2. Rear brake light switch adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04993
Replacing the fuses The main fuse is located under the igni-
tor unit panel.The fuse box, which contains the fuses
for the individual circuits, is located in-
side the storage compartment. (See
page 3-15 for storage compartment
cover removal and installation proce-
dures.)
If a fuse is blown, replace it as follows.
NOTE:_ Include steps 1–3 and 9–10 only for the
main fuse. _1. Remove the rider seat. (See page
3-13 for rider seat removal and in-
stallation procedures.)
2. Remove the quick fasteners
shown by pushing the center in
with a screwdriver, then pulling the
fastener out.
1. Fuse box
2. Headlight fuse
3. Signaling system fuse
4. Ignition fuse
5. Carburetor heater fuse
6. Ignitor unit fuse
7. Odometer and immobilizer system fuse
(backup fuse)
8. Spare fuse (× 3)
9. Turn signal light, taillight, auxiliary light and
hazard fuse
1. Quick fastener (× 3)
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Page 77 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 3. Pull the ignitor unit panel outward
to the right.
4. Turn the key to “OFF” and turn off
the electrical circuit in question.
5. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. _
6. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
7. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
8. Install the storage compartment
cover.
1. Ignitor unit panel
2. Spare main fuse
3. Main fuse
Specified fuses:
Main fuse: 30 A
Odometer and
immobilizer system fuse
(backup fuse): 10 A
Ignition fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse: 15 A
Signaling system fuse: 10 A
Ignitor unit fuse: 5 A
Turn signal light, taillight,
auxiliary light and
hazard fuse: 10 A
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Page 78 of 102
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
69. Place the ignitor unit panel in the
original position and install the
quick fasteners.
NOTE:_ To install a quick fastener, push its pin
back so that it will protrude from the
fastener head, then insert the fastener
and push the protruding pin in until it is
flush with the fastener head. _10. Install the rider seat.
EAU04187
Replacing the headlight bulb This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by re-
moving the screws.2. Disconnect the headlight coupler,
and then remove the bulb cover.
1. Quick fastener
2. Pin
After removal
Before installation
1. Screw (× 2)
1. Headlight bulb cover
2. Headlight coupler
U5KSE4.book Page 29 Wednesday, September 11, 2002 11:55 AM
