EAU50920
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
General manager of quality assurance div.
Date of issue: 1 Aug. 2002 Place of issue: Shizuoka, Japan
DECLARATION of CONFORMITY
YAMAHA MOTOR ELECTRONICS CO., LTD.1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan
Company: YAMAHA MOTOR ELECTRONICS CO., LTD. We
Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan
Kind of equipment: IMMOBILIZER Hereby declare that the product:
Type-designation: 5SL-00
is in compliance with following norm(s) or documents:
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.3.1(2006-01), EN300 330-2 v1.5.1(2010-02)
EN60950-1:2006/A11:2009
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
1
2
3
4 Version up the norm of EN60950 to EN60950-1
To change company name
version up of the following norm:
• EN300 330-2 v1.1.1 to EN300 330-2 v1.3.1 and EN300 330-2 v1.5.1
EN60950-1:2001 to EN60950-1:2006/A11:2009
27 Feb. 2006
1 Mar. 2007
8 Jul. 2010
Revision record
No. Contents
To change contact person and integrate type-designation. Date
9 Jun. 2005
U26PE3E0.book Page 1 Tuesday, June 7, 2011 5:19 PM
TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator lights and warning lights ............................................3-4
Multi-function meter unit .................3-5
Handlebar switches ........................3-8
Clutch lever ...................................3-10
Shift pedal .....................................3-10
Brake lever ...................................3-11
Brake pedal ..................................3-11
Fuel tank cap ................................3-11
Fuel ...............................................3-12
Fuel tank breather/overflow hose ..........................................3-13
Catalytic converter ........................3-14
Rider seat .....................................3-14
Helmet holder ...............................3-15
Adjusting the shock absorber assembly ...................................3-16
Sidestand ......................................3-17
Ignition circuit cut-off system ........3-18 FOR YOUR SAFETY
–
PRE-OPERATION CHECKS ............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner ’s tool kit ............................... 6-2
Periodic maintenance chart for the emission control system ............. 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing the
panel ........................................... 6-8
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Replacing the air filter element ..... 6-12
Checking the throttle grip free play ........................................... 6-13
Valve clearance ............................ 6-13
Tires ............................................. 6-13
Cast wheels .................................. 6-15
Adjusting the clutch lever free play ........................................... 6-15 Adjusting the brake lever free
play ........................................... 6-16
Brake light switches ..................... 6-17
Checking the front and rear brake pads .......................................... 6-17
Checking the brake fluid level ...... 6-18
Changing the brake fluid .............. 6-19
Drive belt slack ............................ 6-20
Checking and lubricating the cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the brake and shift pedals .............. 6-21
Checking and lubricating the brake and clutch levers ............ 6-22
Checking and lubricating the
sidestand .................................. 6-23
Lubricating the swingarm pivots ........................................ 6-23
Lubricating the rear suspension ... 6-23
Checking the front fork ................. 6-24
Checking the steering .................. 6-24
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-25
Replacing the fuses ..................... 6-26
Replacing the headlight bulb ....... 6-28
Replacing the tail/brake light bulb ........................................... 6-29
Replacing a turn signal light bulb ........................................... 6-30U26PE3E0.book Page 1 Tuesday, June 7, 2011 5:19 PM
SAFETY INFORMATION
1-2
1
due to excessive speed or under-
cornering (insufficient lean angle
for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
This motorcycle is designed for on-
road use only. It is not suitable for
off-road use.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
U26PE3E0.book Page 2 Tuesday, June 7, 2011 5:19 PM
SAFETY INFORMATION
1-5
1
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
U26PE3E0.book Page 5 Tuesday, June 7, 2011 5:19 PM
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-17, 6-18
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary. 6-15
Throttle grip
Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 6-13, 6-21
Control cables
Make sure that operation is smooth.
Lubricate if necessary. 6-21
Wheels and tires
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary. 6-13, 6-15
Brake and shift pedals
Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary. 6-21
Brake and clutch levers
Make sure that operation is smooth.
Lubricate lever pivoting points if necessary. 6-22
Sidestand
Make sure that operation is smooth.
Lubricate pivot if necessary. 6-23
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary. —
Instruments, lights, signals
and switches
Check operation.
Correct if necessary. —
ITEM CHECKS PAGE
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 Air filter element Replace. √
2Clutch
Check operation.
Adjust. √√√√√
3 *Front brake
Check operation, fluid level and
vehicle for fluid leakage.
Adjust brake lever free play. √√√√√√
Replace brake pads. Whenever worn to the limit
4 *Rear brake
Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
Replace brake pads. Whenever worn to the limit
5 *Brake hoses
Check for cracks or damage.
Check for correct routing and
clamping. √√√√√
Replace. Every 4 years
6 *Wheels Check runout and for damage. √√√√
7 *Tires
Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary. √√√√√
8 *Wheel bearings
Check bearing for looseness or
damage. √√√√
U26PE3E0.book Page 4 Tuesday, June 7, 2011 5:19 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
9*Swingarm
Check operation and for exces-
sive play. √√√√
Lubricate with lithium-soap-based
grease. Every 50000 km (30000 mi)
10 *Drive belt
Check belt condition.
Replace if damaged.
Check belt tension.
Make sure that the rear wheel is
properly aligned. Every 4000 km (2500 mi)
11 *Steering bearings
Check bearing play and steering
for roughness. √√√√√
Lubricate with lithium-soap-based
grease. Every 20000 km (12000 mi)
12 *Chassis fasteners
Make sure that all nuts, bolts and
screws are properly tightened. √√√√√
13 Brake lever pivot
shaft
Lubricate with silicone grease. √√√√√
14 Brake pedal pivot
shaft
Lubricate with lithium-soap-based
grease. √√√√√
15 Clutch lever pivot
shaft
Lubricate with lithium-soap-based
grease. √√√√√
16 Shift pedal pivot
shaft
Lubricate with lithium-soap-based
grease. √√√√√
17 Sidestand
Check operation.
Lubricate with lithium-soap-based
grease. √√√√√
18 *Sidestand switch Check operation. √√√√√√
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
U26PE3E0.book Page 5 Tuesday, June 7, 2011 5:19 PM
PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
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.TIPThe tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This motorcycle is equipped with tube-
less tires, tire air valves and cast
wheels.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
Tire air pressure (measured on cold
tires):0–90 kg (0– 198 lb):
Front:
225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 250 kPa (2.50 kgf/cm ², 36 psi)
90– 210 kg (198– 463 lb):
Front: 225 kPa (2.25 kgf/cm ², 33 psi)
Rear: 250 kPa (2.50 kgf/cm ², 36 psi)
Maximum load*:
210 kg (463 lb)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear): 1.6 mm (0.06 in)
Front tire:Size: 130/70-18M/C 63H
Manufacturer/model: BRIDGESTONE/EXEDRA G721
J
DUNLOP/D404F
Rear tire:
Size: 170/70B16M/C 75H
Manufacturer/model:
BRIDGESTONE/EXEDRA G722
J
DUNLOP/K555
U26PE3E0.book Page 14 Tuesday, June 7, 2011 5:19 PM