Page 33 of 82
OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17021
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:
ECA11281
After 1000 km (600 mi) of operation,
the engine oil must be changed, and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealercheck the vehicle.
EAU17200
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
5KRE2.book Page 4 Monday, June 23, 2003 3:32 PM
Page 36 of 82
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√ √ √ √
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√ √ √ √ √
11*Wheel bearingsCheck bearing for looseness or damage.√ √ √ √
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√ √ √ √ √
16 SidestandCheck operation.
Lubricate.√ √ √ √ √
17*Sidestand switchCheck operation.√ √ √ √ √ √
18*Front forkCheck operation and for oil leakage.√ √ √ √
19*Shock absorber assem-
bliesCheck operation and shock absorbers for oil leakage.√ √ √ √
20*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√ √ √ √ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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Page 37 of 82
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18660
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 cylinder and caliper, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil filter elementReplace.√ √ √
23*Engine oil strainerClean.√
24*Front and rear brake
switchesCheck operation.√ √ √ √ √ √
25Moving parts and ca-
blesLubricate.√ √ √ √ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√ √ √ √ √
27*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√ √ √ √ √
28*Muffler and exhaust
pipeCheck the screw clamp for looseness.√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√ √ √ √ √ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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Page 41 of 82
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU19751
Engine oil and oil filter
element 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 vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse 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-right side of the
crankcase.
NOTE:The engine oil should be between theminimum 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 element replace-
ment)
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 element isnot being replaced.
4. Remove the oil filter element cover
by removing the bolts.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
1. Engine oil drain bolt
2. Oil pan
5KRE2.book Page 8 Monday, June 23, 2003 3:32 PM
Page 53 of 82
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
Use only the recommended quality
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.
Be careful that water does not en-
ter the master cylinder when refill-
ing. 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 grad-
ually go down. However, if thebrake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22720
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 brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
Recommended brake fluid:
DOT 4
5KRE2.book Page 20 Monday, June 23, 2003 3:32 PM