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PERIODIC MAINTENANCE AND ADJUSTMENT
7-5
7
√ √
21 *Brakes
Adjust lever position and pedal height.
Lubricate pivot points.
Check brake disk surface.
Check fluid level and for leakage.
Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts. √
Replace brake pads. √
Replace brake fluid. Every year√
22 *Front fork
Replace oil seals.
Replace fork oil.
Clean dust seal and lubricate with lithium-soap-based
grease.
Adjust if necessary.
Check operation and for oil leakage.
√
√√√
NO. ITEM ROUTINE
After
break-in Every
race Every
third race Every
fifth race As
required
√
√
√
23 *Shock absorber assem-
bly
Check operation and adjust.
Tighten if necessary.
Lubricate with
lithium-soap-based grease
. √(After
washing the
motorcycle or riding in the rain)
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-6
7
EAU42011
TIP
Hydraulic brake service Regularly check and, if necessary, correct the brake fluid levels.
√
√√
√
24
*Drive chain roller and
support guide
Replace if necessary.
Check for wear or damage.
√
25 *Rear suspension
Check operation and tighten if necessary.
Lubricate with
lithium-soap-based grease
.
NO. ITEM ROUTINEAfter
break-in Every
race Every
third race Every
fifth race As
required
√ √√
√
√ √
√
√ √
√
√
√ √
√
√
26
*Steering head
Check operation, free play, and tighten if necessary.
Clean and lubricate with lithium-soap-based grease.
Replace bearings.
27 *Tires and wheels
Check tire air pressure, wheel runout, spokes for
looseness, and tires for wear.
Tighten sprocket bolts if necessary.
Check wheel bearings for looseness.
Lubricate wheel bearings with lithium-soap-based
grease.
Replace wheel bearings.
28 *Moving parts and ca-
bles
Lubricate.
29 *Throttle grip
Check operation.
Check throttle grip free play, and adjust if necessary.
Lubricate cable and grip housing.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
7
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.
U1SN80E0.book Page 7 Thursday, June 9, 2011 11:24 AM
Page 61 of 88
PERIODIC MAINTENANCE AND ADJUSTMENT
7-17
7
WARNING
EWA14390
Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
sively 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.
It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
EAU48321
Spoke wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.
The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage and the spokes for
looseness or damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
EAU48373
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0 –15.0 mm (0.39 –0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows. 1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the clutch lever free play
adjusting bolt in direction (a). To
decrease the clutch lever free play,
turn the adjusting bolt in direction
(b).
U1SN80E0.book Page 17 Thursday, June 9, 2011 11:24 AM
Page 62 of 88
PERIODIC MAINTENANCE AND ADJUSTMENT
7-18
7
TIPIf the specified clutch lever free play
could be obtained as described above,
skip steps 4–7.4. Fully turn the adjusting bolt in di-
rection (a) to loosen the clutch ca-
ble.
5. Slide the rubber cover back further down the clutch cable, and then
loosen the locknut.
6. To increase the clutch lever free play, turn the clutch lever free play
adjusting nut in direction (a). To decrease the clutch lever free play,
turn the adjusting nut in direction
(b).
7. Tighten the locknut at the clutch cable, and then slide the rubber
cover to its original position.
8. Tighten the locknut at the clutch le- ver, and then slide the rubber cov-
er to its original position.
EAU37913
Checking the brake lever free
play There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14211
A soft or spongy feeling in the brake
lever 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 vehicle. Air in the
hydraulic system will diminish the
1. Clutch lever free play
2. Locknut
3. Clutch lever free play adjusting bolt
4. Rubber cover
1
(a)
23
4
1. Locknut
2. Clutch lever free play adjusting nut
3. Rubber cover
1
2
3
(a)(b)
1. No brake lever free play
U1SN80E0.book Page 18 Thursday, June 9, 2011 11:24 AM
Page 63 of 88
PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
7
braking performance, which may re-
sult in loss of control and an acci-
dent.
EAU44820
Checking the shift pedal The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22392
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 the1. Brake pad wear indicator
U1SN80E0.book Page 19 Thursday, June 9, 2011 11:24 AM
Page 64 of 88
PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
7point that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU46291
Rear brake pads
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
EAU22581
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
Rear brake
WARNING
EWA15990
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
1. Brake pad wear indicator groove
1. Minimum level mark
1. Minimum level markSpecified brake fluid:
DOT 4
U1SN80E0.book Page 20 Thursday, June 9, 2011 11:24 AM
Page 65 of 88
PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
7
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brakefluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
U1SN80E0.book Page 21 Thursday, June 9, 2011 11:24 AM
