Yamaha 4C8-28199-10 manual

4C8-28199-10 YZFR1W(C) OWNER’S MANUAL LIT-11626-20-53[...]

EAU10041 U4C810E0.book Page 1 Wednesday, September 27, 2006 3:06 PM[...]

INTRODUCTION EAU10080 Congra tulati ons on you r purcha se of the Yamaha YZFR1W(C ). This mode l is the r esult of Yamaha ’s vast expe rienc e in the produ ction o f fine sp ortin g, tour ing, and pacese tting racing ma chines. It repr esents the hi gh degr ee of cr aftsman ship an d reli abili ty that hav e made Yamaha a le ader in th ese fields[...]

IMPORTANT MANUAL INFORMATION EAU1013 1 Parti cular ly impo rtant in forma tion is disti nguis hed in this manua l by the foll owi ng nota tions: NOTE: ● This ma nual sho uld be cons idered a permane nt part of this mot orcycle and shou ld remai n with it e ven if th e motor cycle is subs equent ly sold . ● Yamaha continu ally see ks advanc emen[...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BEEN TRAIN ED IN S AFE AND PROP ER RIDIN G TECHNIQUES. REGULAR I NSPECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES A ND THE RE LIABILITY OF THIS MOT ORCYCLE. *Pro duct a nd spe cif icati ons ar e sub ject to chan ge wi thout n otic[...]

IMPORTANT MANUAL INFORMATION EAU10192 YZFR1W(C) OW N E R ’ S MANU AL ©2006 by Y amaha Motor Corporation, U .S.A. 1st edition, September 2006 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U.S.A. is expressl y prohibited. Printed in Japan. P/N LIT -1162 6-20-5 3 AFFIX DEALER L[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. ..... 1-1 Location of import ant labels ........... 1-5 DESCRIPTION ............ ................. ..... 2-1 Left view ............... ................. .......... 2-1 Right view .................. ................. ..... 2-2 Controls a nd instruments ...... .......... 2-3 INSTRUMENT AND CONTROL FU[...]

TABLE OF CONTENTS Replaci ng a turn sig nal light bul b ................. ................. .. 6-40 Replaci ng the li cense pl ate light bul b ................. ................. .. 6-41 Replaci ng an auxil iary ligh t bulb ...6-41 Supporting t he motorc ycle ............6-42 Front wheel ........... ................. .......6-43 Rear wheel ........[...]

1-1 1 SAFETY INFORMATION EAU10281 MOT ORCYC LES A RE SIN GLE TRACK VEHICLES. THEIR SAFE USE AND OPER ATI ON AR E DEPE ND ENT UPON THE USE OF PROPER RIDING TECH NIQ UES AS WEL L AS TH E EX- PERTISE OF THE OPERATOR. EV- ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RID ING THIS MO TOR- CYCL E. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRU[...]

SAFETY INFORMATION 1-2 1 due to EXCESSIVE SPEED or un- derc orneri ng (in suffic ient l ean an- gle fo r the spee d). • Alway s obey the s peed lim it and never trav el f aster than w arra nt- ed by ro ad an d traffi c con dition s. • Alway s signa l befor e turnin g or chan ging lane s. M ake sur e tha t othe r motorists can see you. ● The p[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weight of the o perator, pas- senger, acce ssories and ca rgo must not exce ed the ma ximum load li mit. When lo ading w ithin this weig ht limi t, keep the f ollowing in mind: ● Cargo and a cces sory we igh t shoul d be kept as low an d close t o the mo torcycl e as possibl e. Make sure t o distr ibu [...]

SAFETY INFORMATION 1-4 1 tor an d may limit c ontrol abi lity, therefo re, such accesso ries are not re comm ende d. ● Use ca utio n whe n addi ng el ectr i- cal accesso ries. If electr ical acces - sories e xceed th e capac ity of t he motor cycle ’ s electrica l system, an elec tric failu re coul d result, which could cause a dang erous loss [...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se re ad the f oll owing i mport ant lab els c arefu lly b efore o per ating this v ehicl e. U4C810E0.book Page 5 Wednesday, September 27, 2006 3:06 PM[...]

SAFETY INFORMATION 1-6 1 3 4 1 2 CA UTION Cleaning with alkaline or acid cleaner , gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 California onl y California onl y California onl y HO W T O LA Y OUT FUEL HOSES #1 #2 #3 #4 FUEL DELIVER Y FUEL PUMP FUEL FIL TER PRESS. REGULA T OR 2C0-2178A-00 FUEL T ANK U4C810E0.book Page 6[...]

SAFETY INFORMATION 1-7 1 9 8 5 6 7 WARNING 4C8-2118K-00 BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER ’ S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protectibe clothing. PREMIUM UNLEADED GASOLINE ONLY 91 Min. Pump Octane (R+M)/2 3JJ-28446-A1 290 kPa, {2.90 kgf/cm 2 }, 42psi 5VY -21668-00 U4C810E0.book [...]

DESC RIPTION 2-1 2 EAU1041 0 Left view 1. Fuse box (page 6-35) 2. F ront fork rebound damping f orce adjusting screw (page 3-17) 3. F ront f ork spr ing preload adjusting bolt (page 3-17) 4. Fuel injection system fuse (page 6-3 5) 5. Main fuse (page 6-35) 6. Shock absorber assembly compression damping f orce adju sting bolt (for f ast compression d[...]

DESCRIPTI ON 2-2 2 EAU10420 Right view 1. Luggage strap holder (page 3-21) 2. Helmet holder (page 3-16) 3. Owner ’ s tool kit (page 6-1) 4. P assenger seat lock (page 3-15) 5. Battery (page 6-34) 6. Air filt er element (page 6-19) 7. Radiator cap (page 6-16) 8. Coolant reservoir (page 6-16) 9. Engine oil le v el check window (page 6-13) 10.Engine[...]

DESC RIPTION 2-3 2 EAU1043 0 Controls and instruments 1. Clutch le ver (page 3-12) 2. Left handlebar s witches (page 3-11) 3. Main switch/steering lock (page 3-1) 4. Multi-function meter unit (page 3-5) 5. F ront brake fluid reser voir (page 6-27) 6. Right handlebar switches (page 3-11) 7. Throttle grip (page 6-21) 8. Brake le v er (page 3-12) U4C8[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steer ing lock The main switch/ste ering lock co ntrols the igniti on an d ligh ting syst ems, and is used t o lock th e stee ring. Th e variou s posi tions ar e descr ibed be low. EAU10600 ON All el ectric al cir cuits are sup plied with power , the m eter li ghting , tail light , li- cen[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-2 3 To unl ock the steering Push the key in, a nd th en tu rn it to “ OFF ” whi le still pu shing it. W ARNI NG EWA10060 Never tur n the ke y to “ OFF ” or “ LOCK ” whi le t he veh icle i s movi ng, otherw ise the el ectric al sys tems wi ll be swit ched off , which may resul t in loss of control or a[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 ● This mo del is also equipp ed with a self- diagnosi s device for th e oil level detecti on cir cuit. If th e oil lev - el detec tion ci rcuit is defect ive, the follo wing cycle w ill be repeat ed un- til t he malf unction i s correct ed: The oil le vel warni ng ligh t wil l flas h ten times, then go of f [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-4 3 Coolant temp erat ur e Displa y Condi tions What to do Under 39 ° C (Under 103 ° F) Mess age “ Lo ” is display ed. OK. Go ahead with riding. 40 – 116 ° C (104 – 242 ° F) T emperature is display ed. OK. Go ahead with riding. 117 – 139 ° C (243 – 283 ° F) T emperature display flashes. W ar nin[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 EAU11530 Engine trouble warning light “” This wa rning lig ht come s on or fla shes when an elec trical circui t monit oring the engine is defe ctive. When this occurs, have a Yamaha dealer ch eck the s elf- diagno sis system. (See pa ge 3-5 for an expl anatio n of th e se lf-di agnosi s de- vice.) The el [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-6 3 ● a speedo meter (w hich show s the riding spe ed) ● a tachom eter (whi ch shows en gine speed) ● an od ometer (whic h sh ows th e to- tal dist ance tra veled) ● two tri pmeter s (whic h show th e dista nce tra veled sinc e th ey wer e last set to zero) ● a fuel reserve tr ipmeter (which shows t he [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 3. Push the “ SELEC T ” button , and the mi nute dig its will start f lashing . 4. Push t he “ RESET ” butt on to s et the mi nutes. 5. Push the “ SELEC T ” butto n and then releas e it t o sta rt the clock. Odometer, tripmeter, and stopwatch modes Push the “ SELECT ” button to swit ch the dis [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-8 3 Coolant temper ature disp lay The c oolant temper ature d isplay indi- cates the te mpera ture o f the cool ant. Push the “ RESET ” butt on to s witch the cool ant temp erat ure displ ay to t he air inta ke tem per ature disp lay. N O TE: When the coolan t tempe ratur e displa y is se lec ted, “ C ” i[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 CAUTION: ECA11590 If th e displ ay in dicat es an err or code, the vehicle should be checked as soon as possibl e in order to avoid engine damage . Display brightness and shift timing indicator light control mode This mo de cycle s through f ive con trol func tions, allow ing you to make t he fol- lowin g se t[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-10 3 ● The indica tor light will stay on when a ctivate d. ( This set ting is sel ect ed wh en the i ndica tor light stays o n.) ● The in dicato r light will f lash when a ctivate d. ( This set ting is sel ect ed wh en the i ndica tor ligh t flash es four ti mes pe r second. ) ● The indic ator light is deac[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 EAU12347 Handleb ar swi tches Left Right EAU12400 Dimmer switch “ / ” Set this s witch to “” for the hi gh beam an d to “” for th e lo w bea m. EAU12460 Turn signal s witch “ / ” To sign al a r ight-ha nd turn , push t his switch to “” . To sign al a l eft-ha nd turn, push this sw itch to [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-12 3 EAU12820 Clutch lever The clu tch lever is l ocated at the left handle bar grip. To dise ngag e the clutc h, pull the lever toward the h andle- bar gr ip. To e ngage the clu tch, r ele ase the lev er. T he le ver s houl d be p ulle d rapid ly and rel eased slow ly for smooth clutc h operat ion. The c lutch l[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-13 3 it by alig ning a gro ove on the a djustin g knob wi th the “” m ark on th e brake lever. EAU12941 Brake pe dal The brake pedal is on the right side of the moto rcycle. To appl y the rear brak e, pres s down on the br ake ped al. EAU13072 Fuel tank cap To open the fuel tank cap Open th e fuel tank ca p lo[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-14 3 NOTE: The fu el tank cap c annot be clos ed un- less th e key is in the lock. In addition , the key cannot be r emove d if the c ap is not pr operl y clo sed an d lo cked. W ARNI NG EWA11090 Make su re tha t the f uel t ank ca p is properly closed before riding. EAU13220 Fuel Make s ure th at th ere is s uff[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-15 3 octane number of 95 o r higher . If knocking (or pinging) occurs, use a gasolin e of a diff eren t brand. Use of un- leaded fuel will extend spark plug l ife and redu ce mainten ance cost s. Gasohol There are two type s of g asoho l: ga so- hol cont aining et hanol and t hat cont ain- ing met hanol . Gaso hol[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-16 3 Passen ger seat To re move t he passe nger seat 1. I nsert the key into th e seat lo ck, and the n turn it clockwise. 2. Li ft th e fro nt of th e passe nger sea t and pull it forw ard. To ins tall the pas seng er seat 1. I nsert the proj ection on the r ear of the pas senge r seat into the s eat holde r as [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-17 3 To release a helmet from a helmet holder Rem ove the pa ssen ger seat , remo ve the he lmet f rom the helmet holde r, an d then in stall th e seat. EAU14741 Adjusting the front fork This f ront f ork is equipp ed wit h sprin g prel oad adju sti ng bolts , reboun d damp - ing fo rce adjusti ng screw s and com-[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-18 3 Rebound damping force To inc rease the rebo und dam ping fo rce and ther eby ha rden th e rebou nd dam p- ing, t urn the ad justing scr ew on ea ch fork leg in direc tio n (a) . To de crea se th e rebo und damp ing force an d there by softe n the rebo und damp ing, tu rn the adjust ing screw on each fo rk le[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-19 3 EAU42940 Adjusting the s hock absorber assem bly This shock a bsorber as sembly is equip ped wi th a spring preloa d adju st- ing rin g, a reboun d dampin g force ad- justing screw, a compress ion damp ing force adju sting bolt (for fast compre s- sion dampi ng) an d a com press ion dampin g force a djustin g[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-20 3 Compression damping force Compre ssion d ampin g for ce (for fast compre ssion dampin g) To increa se the comp ression dam ping force and ther eby ha rde n the com pres- sion da mping , turn the adju sting bolt i n direction (a). To decrease the compres- sion dam ping fo rce and the reby soft en the c ompres[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-21 3 the following in formation before handling the shock a bsorber. The manufacturer cannot be held re- sponsible for property damage or personal in jury that may resul t from improper hand ling. ● Do not tamper with or attempt to open the gas cylinder. ● Do not su bject the shoc k ab- sorber to an open flame[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-22 3 EAU15301 Sidestand The si dest and is lo cate d on the le ft sid e of th e frame. Raise t he side stand or lower it with yo ur fo ot whi le hold ing th e vehicle upright. NOTE: The bu ilt-i n si desta nd sw itch is pa rt of the igni tion c ircuit cut-off s ystem , which cuts t he igni tion in certai n situa [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-23 3 With the engine turned off: 1. Move the sidestand do wn. 2. Make sure that the engine stop switch is turned on. 3. T urn the ke y on. 4. Shift the transmission into the neutral position. 5. Push the star t s witch. Does the engine start? With the engine still running: 6. Move the sidestand up . 7. Keep the cl[...]

PRE-OPERATION CH ECKS 4-1 4 EAU15592 The con dition of a vehicle is th e owner ’ s respo nsibi lity. Vi tal comp onents can sta rt to deterio rate q uickly an d unex pected ly, even if the v ehicle remain s unused (for example , as a re sult of exposu re to t he elem ents). Any dama ge, fl uid l eakage or los s of tir e air p ressur e cou ld ha v[...]

PRE-OPERATION CHE CKS 4-2 4 EAU15605 Pre-operation check list ITEM CHECKS P A GE Fuel • Check fuel le vel in fuel tank. • Refuel if necessar y . • Check fuel line for leakage. 3-14 Engine oil • Check oil le vel in engine. • If necessar y , add recommended oil to specified lev el. • Check vehicle f or oil leakage. 6-13 Coolant • Check [...]

PRE-OPERATION CH ECKS 4-3 4 Thr ottle grip • Make sure that oper ation is smooth. • Check cable free pla y . • If necessar y , have Y amaha dealer adjust cable free play and lubricate cable and grip housing. 6-21, 6-30 Contr ol cables • Make sure that oper ation is smooth. • Lubricate if nece ssar y . 6-30 Drive chain • Check chain slac[...]

OPERATION AND IMPORTANT RIDING PO INTS 5-1 5 EAU15950 W ARNI NG EWA10270 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it i n a closed area for an y length of ti[...]

OPERATION AND IM PORTANT RIDING POINTS 5-2 5 CAUTION: ECA11130 For maximum engine li fe, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The e ngine is w arm wh en it qui ckly re - sponds to the thro ttle. EAU16671 Shifting Shifti ng ge ars let s you con trol th e amount of engin e power ava ilabl[...]

OPERATION AND IMPORTANT RIDING PO INTS 5-3 5 4. At th e recom mend ed s hift po ints sho wn in the fo llowin g table, close the thr ottle, and at th e sam e time , quickl y pull the clutch l ever in. 5. Shif t the trans mis sion i nto s eco nd gear. (M ake su re not t o shift the transm ission int o the neutra l posi- tion.) 6. O pen th e thro ttle[...]

OPERATION AND IM PORTANT RIDING POINTS 5-4 5 CAUTION: ECA10301 After 1000 km (600 mi) of operation, the engine oil must be changed and the o il fil ter c artri dge or el ement re- plac ed. 1600 km (10 00 mi) an d bey ond The vehi cle c an now be oper ated no r- mally . CAUTION: ECA10310 ● Keep the engine speed out of the tachometer red zone. ● [...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-1 6 EAU17231 Safety is an ob ligati on of th e owne r. Pe- riod ic ins pecti on, ad justm ent an d lubr i- cation will keep yo ur vehicle in the safest and most effici ent cond ition pos- sible. The most im portan t points of motor cycle inspe ction, adj ustment, and lubri cation a re expl ained o n the fol[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-2 6 W ARNI NG EWA10340 Modifications not approved by Yamaha may cause loss of perfor- mance, excess ive e missi ons, and render the ve hicle u nsaf e for us e. Consult a Yamaha dealer before at- tem pting any change s. W ARNI NG EWA12371 Do not tou ch eit her m uffler brac ket, located under the muffler brac[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-3 6 EAU17600 Periodi c mainte nance c hart fo r the em ission contr ol syst em * Since t hese it ems req uire s pecial to ols, data and tech nical s kills, hav e a Yama ha dea ler perfor m the se rvic e. No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 80[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-4 6 EAU32183 General maintenance and lubrication chart No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 mo nths 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter elemen[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-5 6 9 * Swingar m piv ot beari ngs • Check bearing assemblies f or looseness. • Moderately repack with lithium- soap-based grease. √ Repack. 10 Drive chain • Check chain slack, ali gnment and condition. • Adjust and lubr icate chain with a special O-ring c hain lubricant thoroughly . Every 500 mi [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-6 6 17 * Sidestand switch • Check operation and replace if necessar y . √√√√√ √ 18 * Fron t fo rk • Check operation and for oil leak- age. • Replace if necessar y . √√√√√ 19 * Shock absorber as- semb l y • Check operation and for oil leak- age. • Replace if necessar y . √√[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-7 6 * Since t hese it ems req uire s pecial to ols, data and tech nical s kills, hav e a Yama ha dea ler perfor m the se rvic e. NOTE: From 24 000 mi (3700 0 km) or 36 mon ths, re peat th e mainte nance interv als st arting from 800 0 mi (13 000 km ) or 12 m onths. EAU17650 NOTE: ● Air f ilte r • This m[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-8 6 • Replac e the b rake hos es ev ery four ye ars and if cr acke d or d amag ed. U4C810E0.book Page 8 Wednesday, September 27, 2006 3:06 PM[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-9 6 EAU18712 Removing and installing cowl- ings and panels The cowl ings an d pane ls show n need to be r emoved to per form so me of th e mainte nance jo bs describe d in this chapt er. R efer to th is sect ion ea ch time a cowlin g or pan el needs to be re- moved an d instal led. EAU42970 Cowlings A and B[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-10 6 2. D isconnec t the tur n signal light lead c oupler. To insta ll the c owling 1. C onnect the tur n sign al ligh t lead coupler . 2. F it the p roject ions o n the cow ling into th e slots an d slide it forward. 3. Instal l the quick fasten ers a nd th e quick f astener screws. EAU42951 Cowling C To re[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-11 6 To instal l the cowlin g 1. Insert the p rojec tions into the s lots , and then slid e the cowlin g for ward. 2. Place the cow ling in i ts or igina l po - sit ion, an d then i nstal l the qui ck fastene r scr ews an d the bolts . 3. Instal l cowl ing A. EAU33990 Panels A and B To rem ove o ne of the p[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-12 6 EAU19652 Checki ng the spa rk plugs The spa rk plugs are impo rtant en gine compon ents , which s hould be checke d perio dical ly, preferab ly by a Yamaha dealer . Since he at and de posit s will cause any spark plug to s lowly erode, they sho uld be rem oved and ch ecked in ac cordance with the pe rio[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-13 6 NOTE: If a tor que wre nch is not availabl e when install ing a spark plu g, a good estimate of the c orrec t torqu e is 1/4 – 1/2 t urn past fi nger t ight. Ho wever , the spar k plug s hould be tightene d to the spec i- fied torq ue as soon as poss ible . CAUTION: ECA10840 Do not use any tools to r[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-14 6 NOTE: The en gine o il sho uld be betw een th e minimu m and maxi mum level mar ks. 4. If the engi ne o il is a t or b elow the mini mum level mark, ad d suffic ient oil o f the re commen ded typ e to rais e it to t he cor rect leve l. To change the engine oil (with or without oil filter cartridge repla[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-15 6 N O TE: Make sure th at the O-r ing is properl y seated . 7. Instal l the new oi l filter cartrid ge with an o il fil ter wr ench, and th en tighten it to th e speci fied to rque with a t orque wrench. 8. I nstall the eng ine oil dr ain bolt , and then tighte n it to t he specif ied torque . NOTE: Chec[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-16 6 NOTE: After the engine is sta rted, the engine oil le vel wa rning ligh t shou ld go off if the oil leve l is sufficien t. CAUTION: ECA10400 If the oil leve l warning li ght flicker s or remains on, imm ediately turn the engine off and have a Yamaha dealer check the ve hic le. 11. Turn t he en gine off,[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-17 6 CAUTION: ECA10471 ● If coolant is not available , use distilled water or soft tap water instead. Do not use hard water or salt water since it is harm ful to the engine. ● If wate r has b een us ed ins tead of coolant, replace it with cool- ant as soon as possible, other- wise the cooling sys tem wi[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-18 6 6. Remove the coola nt reservoir cap. 7. Remove the co olant reservo ir by remo ving the bolts , and th en turn the r eservo ir upsi de do wn to em p- ty it. 8. After th e co olant i s comp letely drai ned, tho roughl y flus h the c ool- ing syste m with clean tap water . 9. Instal l the c oolan t re se[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-19 6 the coolant as soon as possible , othe rwise t he effec tiven ess of the coolant will be reduced. 13. Insta ll the ra diat or cap, s tart t he engine, let i t idle for several min- utes, a nd th en tur n it off. 14. Remove t he radi ator cap to che ck the co olant l evel in t he radia tor. If nece ssar[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-20 6 CAUTION: ECA12880 When re movi ng the ai r filt er case cover , be ca refu l not to allow f oreig n objects to drop into the air intake manifold. 6. Pull th e ai r filter elem ent o ut. 7. Install a new air fi lter elem ent by f it- ting the pr ojectio ns on t he elem ent into the sl ots in the air filt[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-21 6 ● Be su re to place the f uel ta nk brea ther/ overf low hos e in its original position. 10. Install the panels. 11. Install the rid er seat. EAU21382 Checking the throttle ca ble free play The th rottl e cable free play shoul d mea - sure 3.0 – 5.0 mm (0. 12 – 0.20 in) at the throttle grip. P er[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-22 6 EAU21750 Tires To max imiz e the perfor manc e, dura bil- ity, an d safe op eration of your motor - cycle, no te the following points regar ding the sp ecified tires. Tire air pressur e The tire ai r pres sure s hould be checked and, if necessary , adjust ed before ea ch ride. W ARNI NG EWA10500 ● The[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-23 6 Always che ck the tires befo re operatin g the moto rcycle. If a tire tr ead show s crosswise lines (m inimum tread depth), if the tire ha s a nail o r glass f ragment s in it, or if the side wall i s cracked , con- tact a Yam aha de aler im medi ately and have the t ire rep laced . W ARNI NG EWA10580 [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-24 6 W ARNI NG EWA10600 This motorcycle is fitted with s uper- high-speed tires. Note the following points in or der to make the most ef- ficient use of these tires. ● Use only the speci fied re place- men t tir es. Ot her t ire s may run the danger of bursting at super high speeds. ● Bran d-new ti res c[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-25 6 any consequences caused by the use of items which have not been approved by Yamaha. EAU33890 Adjusti ng the clutch le ver fre e play The c lutch leve r free play s hould m ea- sure 10. 0 – 15.0 mm (0.39 – 0.59 in ) as shown. Period ically chec k the c lutch l e- ver free pl ay an d, if neces sary ,[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-26 6 EAU22270 Adjusting the rear brake light switch The re ar brake light swit ch, whi ch is ac- tivate d by the bra ke pe dal, is pr operl y adjus ted wh en th e brak e ligh t come s on jus t befo re br akin g take s effe ct. If necessary, adjust the brake light sw itch as follo ws. Turn the adj usting nut [...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-27 6 EAU22580 Checking the brake fluid level Front brake Rear b rake Insuf ficie nt brake fluid m ay all ow air to enter the br ake syst em, po ssibly cau s- ing it to become inef fective. Befor e ridin g, chec k that th e br ake flu id is above the m inimum level m ark and repl enish if neces sary. A low b[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-28 6 EAU22730 Changing the brake fluid Have a Y amaha de aler cha nge the brak e fluid a t the inte rvals speci fied in the NO TE afte r t he per iodic main te- nance a nd lubr icati on chart. In addi tion, have the oi l seals of th e master cyl in- ders and cali pers a s well as the b rake hoses replace d a[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-29 6 NOTE: Using the a lignm ent m arks on each side of th e swingarm, make sure th at both c hain pullers are i n the s ame posi- tion for proper whe el alig nment. CAUTION: ECA10570 Improp er drive ch ain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-30 6 CAUTION: ECA11110 Do not use engine oil or any other lu- bric ants f or the dri ve chain , as th ey may contain substances that could damage the O-rings. EAU23091 Checki ng and lubricating t he cables The o peration of all co ntrol ca bles and the co ndition of the ca bles sho uld be checked before each[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-31 6 EAU23140 Checking and lubricating the brake and clutch levers Brak e lever Clut ch l ever The o perati on o f the b rake an d cl utch leve rs sh ould be c hec ked b efor e ea ch ride, an d the leve r pivots sh ould be l u- bricat ed if necess ary. EAU43070 Checking and lubricating the shift pedal The o[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-32 6 EAU23200 Checking and lubricating the sidest and The o peration o f the si destan d should be ch ecked bef ore e ach r ide, and the side stand piv ot and metal -to-m etal conta ct surface s should be lu bricated if necessary. W ARNI NG EWA10730 If the sidestand does not move up and down smoothly, have a[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-33 6 CAUTION: ECA10590 If any damage is found or the front fork does not operate smoothly , have a Yamaha deale r chec k or re - pair it. EAU23280 Checking th e steering Worn or lo ose steer ing be arin gs ma y caus e danger . Theref ore, the opera tion of the steerin g must be checked as fol- low s at the [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-34 6 EAU23290 Checking the wheel bearings The fron t and rear w heel be arings must be chec ked at the intervals sp ecified in the pe riodi c mainte nance an d lubric a- tion ch art. If ther e is pl ay in th e whee l hub or if the whee l does not turn smoot hly, have a Yama ha dealer check the wh eel bear in[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-35 6 ● KEEP THIS AND A LL BATTER- IES OUT OF THE REACH OF CHILDREN. To store the battery 1. If the vehicle will no t be us ed for more than one mon th, re move th e batter y, full y charge it, an d then place it in a co ol, dr y pla ce. 2. If the batter y will be stored for more than two mo nths, check it[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-36 6 To acce ss the fuel in jection sys tem fuse The fuel i njection s ystem fuse is locat- ed und er th e fuel tank and can be ac - cessed a s follows: 1. Lift t he fu el tank . (Se e page 6-19. ) 2. Pull up the r ubber da mper as shown. To ac cess th e fuse bo x The fu se bo x, whic h co ntains the f uses [...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-37 6 To replace a fuse If a fuse is blown, replac e it as fol lows. 1. Turn the key to “ OFF ” and t urn of f the electr ical circu it in questi on. 2. Remove th e blown f use, and t hen instal l a new fus e of the sp ecifi ed ampera ge. CAUTION: ECA10640 Do not use a fuse of a higher amper- age rating [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-38 6 3. Unhook the h eadlig ht bu lb ho lder, and th en rem ove the de fectiv e bulb. W ARNI NG EWA10790 Headlight bulbs get very hot. There- fore, keep flammable products away from a lit head light bulb, a nd do not touch the bulb until it has cooled down. 4. Place a new headlig ht bulb int o po- sition, an[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-39 6 2. Discon nect the he adligh t couple r. 3. Unhook t he headl ight bu lb hold er, and the n re move t he de fecti ve bulb . W ARNI NG EWA10790 Headlight bulbs get very hot. The re- fore, keep flamma ble products away from a lit headlight bulb, and do not touch the bulb until it ha s cooled down. 4. Pla[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-40 6 5. Connect the headlig ht coup ler. 6. Install t he headlight bulb cove r by turning it clockwise. 7. Have a Yamaha dealer ad just the headli ght bea m if necess ary. EAU24180 Tail/brake light This mo del is equ ipped with an LED typ e of tail /brake li ght. If th e tail/ brake light doe s not c ome on,[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-41 6 EAU24310 Replacing the license plate light bulb 1. Remove the lic ense p late ligh t un it by rem oving th e screws. 2. Remove the so cket (toge ther with the bu lb) by pull ing it out. 3. Remove the de fecti ve bu lb by pu ll- ing it out. 4. Insert a new bulb i nto t he sock et. 5. Install the socket [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-42 6 3. Remove the socket (toget her wit h the bu lb) by pu lling it o ut. 4. Remove the def ective bu lb by pull- ing it ou t. 5. Insert a ne w bulb in to the soc ket. 6. Install th e socket (tog ether w ith the bulb) by pu shing it in. 7. Instal l the auxi liar y light bul b cover by i nstalling the quick [...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-43 6 a jack ei ther un der eac h side o f the fram e in f ront o f the rear w heel or und er each si de of the swingar m. EAU24360 Front wheel EAU34591 To remove the fron t wheel W ARNI NG EWA10820 ● It i s advi sable t o have a Yam aha dealer service t he whee l. ● Securely support the motor- cycle so [...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-44 6 CAUTION: ECA11050 Do not apply the brake after the brake calipers have be en removed, otherwise the brake pads will be forc ed shut. EAU34531 To install the front wheel 1. Lift th e wheel up between t he fork legs. 2. Insert the wheel ax le. 3. Lower the f ront wh eel so th at it i s on the g round . 4.[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-45 6 11. Ret ighten pinc h bol t D to the sp ec- ifie d torq ue. 12. While ap plying th e front br ake, push d own ha rd on the ha ndleba r several times to check for proper for k opera tion. EAU25080 Rear wheel EAU25311 To re move t he rear whe el W ARNI NG EWA10820 ● It i s advi sable t o have a Yam aha[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-46 6 CAUTION: ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be fo rced shut. EAU25661 To in stall th e rea r wh eel 1. Install t he whe el and the bra ke cal - iper brack et b y inse rtin g the whee l axle f rom the le ft-han d si[...]

PERIODI C MAINTENANCE AN D MINOR REPAIR 6-47 6 EAU42500 Troubleshooting charts Starting problems or poor engine performanc e W ARNI NG EWA10840 Keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel[...]

PERIODI C MAINTENANCE AND MINOR REPAIR 6-48 6 Engine overheating W ARNI NG EWAT1040 ● Do not remove the radiator cap when the engine and radiator are h ot. Scalding hot fluid and steam ma y be blown out under press ure, which coul d cause serious in jury. Be sure to wait until the engine has cooled. ● Place a thick rag, like a towel, ov er the [...]

MOTORCYC LE CARE AN D STORAGE 7-1 7 EAU37833 Matte c olor caution CAUTION: ECA15192 Some models a re equipped with matte colored fini shed parts. Be sure to consult a Yamaha dealer for advice on what products to us e be- fore cl eaning the vehic le. Us ing a brush, harsh chemical p roducts or cleaning compounds when cleaning these parts will scratc[...]

MOTORCY CLE CARE AND STORAGE 7-2 7 ● Do not use any harsh chemical products on plastic parts or the muffl ers. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electro- lyte. ● Do not use h[...]

MOTORCYC LE CARE AN D STORAGE 7-3 7 not be thorou ghly cl eaned wit h mil d deterge nt, alk aline pr oducts and a s oft b rush may be used . ● Never u se compou nds or oth er speci al tr eatme nts to clea n the tita- nium m uffle rs, a s they will remo ve the fini sh on the outer s urfac e of the muf flers . ● Even the sma llest amou nts of oil[...]

MOTORCY CLE CARE AND STORAGE 7-4 7 EAU26201 Stor age Short-term Alway s stor e your mo torcyc le in a co ol, dry pl ace and, if necessary, protect it agains t dus t with a por ous cov er. CAUTION: ECA10810 ● Storing the motorcycle in a poorly ventilated room or cover- ing it with a tarp, while i t is s till wet, will allow water and humid- ity to[...]

SPECIFICATIONS 8-1 8 Dimensions: Overall le ngth: 2060 mm (81.1 in) Overall w idth: 720 mm ( 28.3 in) Overall h eight: 1110 mm (43.7 in) Seat heig ht: 835 mm ( 32.9 in) Wheelb ase: 1415 mm (55.7 in) Groun d clearan ce: 135 mm (5.31 in) Minimu m turni ng radi us: 3400 mm (133.9 in ) Weight: With oil an d fuel: 199.0 kg (439 lb ) Engine: Engine ty pe[...]

SPECI FI CAT IONS 8-2 8 Gear ratio: 1st: 38/15 (2. 533) 2nd: 33/16 (2. 063) 3rd : 37/21 (1. 762) 4th: 35/23 (1. 522) 5th: 30/22 (1. 364) 6th: 33/26 (1. 269) Chassis: Frame type : Diamon d Caster angle: 24.0 0 ° Tra il: 102.0 mm (4. 02 in) Front tire: Type : Tubele ss Size: 120/7 0 ZR17M /C (58W ) Manuf acturer /mode l: PIRELLI/DIAB LO CORSA E Manu[...]

SPECIFICATIONS 8-3 8 Electrical system: Ignition system: Transisto rized coil ign ition (digital) Chargin g syst em: AC magn eto Battery: Model : YTZ10S Voltag e, capacit y: 12 V, 8.6 Ah Headlight: Bulb type: Halogen bu lb Bulb voltage, wattage × quantity: Headligh t: 12 V, 55.0 W × 4 Tail/bra ke light: LED Front turn signal/position light: 12 V,[...]

CONSUMER INFORMA TION 9-1 9 EAU26351 Identification numbers Record th e key id enti ficatio n numb er, vehicl e ident ifica tion number and mod- el labe l info rmati on in the spac es pro - vided be low for as sistance when order ing sp are pa rts fr om a Yam aha dealer or for refere nce in case th e veh i- cle is sto len. KEY IDENTIFICATION NUM BE[...]

CONSUMER INFORMATI ON 9-2 9 EAU33941 Model label The mode l labe l is affix ed to the fr ame under the passeng er seat. (See page 3-15. ) Recor d the i nformat ion on this l a- bel in the s pace pr ovided. This in forma- tion will be needed when o rderin g spar e par ts fro m a Yama ha d eale r. W ARNI NG EWA12371 Do not touch either m uffler brack[...]

CONSUMER INFORMA TION 9-3 9 EAU26551 Reporting safety defects If you be lieve that your vehi cle has a defec t which coul d cause a cra sh or coul d cause injur y or death , you shoul d immediat ely infor m the Na tion al Hig hway Tra ffic S afety Admi nistra tion ( NHTSA) i n ad dition to noti fying Yamaha Motor Corpo ration, U.S.A. If NHTSA recei[...]

CONSUMER INFORMATI ON 9-4 9 EAU26560 Motorcycle noise r egulation TAMPERING WITH NOISE CONTROL SYSTEM PR OHIBITED: Fede ral law proh ibit s the foll owin g act s or the cau sing thereo f: (1) T he remo val or rende ring i nope rativ e by an y pers on othe r tha n for pur poses of ma intena nce, repair , or r eplace ment of any de vice or el ement o[...]

CONSUMER INFORMA TION 9-5 9 EAU26632 Maintenance record Copie s of work o rders an d/or r eceipts for parts purcha sed and in stalle d on your ve hicle wil l be req uired to documen t that mainte nanc e has be en co mple ted in a ccorda nce with th e emiss ions warran ty. The char t below is pri nted o nly as a remind er that main tena nce work is [...]

CONSUMER INFORMATI ON 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintena nce inter val Date of service Mileage Ser vicing dealer name and address Remarks U4C810E0.book Page 6 Wednesday, September 27, 2006 3:06 PM[...]

CONSUMER INFORMA TION 9-7 9 EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY a) b) c) d) e) f) 1. 2. Y amaha Motor Cor poration, U.S .A. hereby warr ants that new Y amaha motorcycles will be free from def ects in material and workmanship for the period of time stated herein, subject to cer tain stated limitati[...]

CONSUMER INFORMATI ON 9-8 9 W ARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period? The customer ’ s responsibility includes all costs of normal maintenance ser vices, non-warranty repairs , accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes . What are some examples[...]

CONSUMER INFORMA TION 9-9 9 EAU26750 YAMAHA EXTEND ED SERVICE (Y.E.S.) K eep your Y amaha protected e ven after y our warranty expires with gen uine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co verage f or e xtr[...]

CONSUMER INFORMATI ON 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right awa y , and you ’ ll rest easy knowing you ’ ll hav e strong factory-back ed protection ev en after your Y amaha Limited W arranty expires . A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with you[...]

INDEX A Accessories and replacement par ts . ..... 6-24 Air filter element, rep lacing .. ................. 6-19 Auxiliar y light bul b, replac ing ......... ....... 6-41 B Batte ry......... ...... ...... ....... ...... ...... ....... .... 6-3 4 Brake and clut ch levers, checking and lubricating ..................... 6-31 Brake fluid, changing ....[...]

INDEX Throttle grip a nd cable, checking and lubricating ....... ...... ....... . 6-30 Tires......... ...... ...... ....... ...... ...... ...... ....... . 6-22 Tool kit ......... ...... ...... ....... ...... ...... ....... ..... 6-1 Troubleshooting .................... ................ 6-46 Troubleshooting charts ....... .................. 6-47 Tur[...]

A5-yoko_Blank.fm P age 1 Tues day, April 8, 2003 11:43 A M[...]

A5-yoko_Blank.fm P age 1 Tues day, April 8, 2003 11:43 A M[...]

PRINTED IN JAPAN 2006.10-4.2 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD .[...]