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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24Engine oil filter car-
tridgeReplace.√√√
25*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
26*Front and rear brake
switchesCheck operation.√√√√√ √
27Moving parts and ca-
blesLubricate.√√√√ √
28*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
29*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace any damaged parts if necessary.√√√√ √
30*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
31*EXUP systemCheck operation, cable free play and pulley position.√√√
32*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U5VYE1E0.book Page 4 Tuesday, September 7, 2004 9:09 AM
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18680
NOTE:
Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
615. Install and tighten the quick fasten-
er screws, and then install the bolt.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU34011
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in an incorrectreading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
brake fluid reservoir bracket bolt,
remove the coolant reservoir cap,
and then add coolant to the maxi-
mum level mark.
1. Slot
2. Projection
1. Maximum level mark
2. Minimum level mark
1. Brake fluid reservoir bracket bolt
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6
CAUTION:
ECA10470
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
4. Install the coolant reservoir cap,
and then install the brake fluid res-
ervoir bracket bolt.NOTE:
The radiator fans are automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see page6-42 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
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6-18
6
NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and airpressure before each ride.Tire 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 sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
WARNING
EWA10470
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability 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
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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6
EAU22270
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).
EAU22390
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.
EAU22410
Front brake pads
Each front brake pad is provided with a
wear indicator, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicator while applying the
brake. If a brake pad has worn to thepoint that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator
1. Lining thickness
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU22580
Checking the brake fluid level Front brake
Rear brake
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 fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system 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 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 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 grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5VYE1E0.book Page 22 Tuesday, September 7, 2004 9:09 AM
