tdm900 PDF

OWNER’S MANUAL
TDM900
5PS-28199-E1
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5PS-28199-E1 8/29/02 9:16 AM Page 1
EAU04575
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of the TDM900, you are benefiting from Yamaha’s vast experience and newest technol-
ogy regarding the design and manufacture of high-quality products, which have earned Yamaha a
reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM900.
The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcy-
cle, but also in how to safeguard yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible
condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

5PS-28199-E1 8/29/02 9:16 AM Page 2
EAU00005
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
Q IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death

w
to the motorcycle operator, a bystander, or a person inspecting or repairing
the motorcycle.
cC A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.

5PS-28199-E1 8/29/02 9:16 AM Page 3
IMPORTANT MANUAL INFORMATION

EW000002
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.

5PS-28199-E1 8/29/02 9:16 AM Page 4
EAU04229
TDM900
OWNER’S MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st edition, August 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

5PS-28199-E1 8/29/02 9:16 AM Page 5
EAU00009
TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY 1
2 DESCRIPTION 2
3 INSTRUMENT AND CONTROL FUNCTIONS 3
4 PRE-OPERATION CHECKS 4
5 OPERATION AND IMPORTANT RIDING POINTS 5
6 PERIODIC MAINTENANCE AND MINOR REPAIR 6
7 MOTORCYCLE CARE AND STORAGE 7
8 SPECIFICATIONS 8
9 CONSUMER INFORMATION 9
INDEX

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5PS-28199-E1 8/29/02 9:16 AM Page 7
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY ...............................................1-1

1

5PS-28199-E1 8/29/02 9:16 AM Page 8
EAU00021
QGIVE SAFETY THE RIGHT OF WAY

Safety information
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-
dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
Enjoy your ride!
1-1

5PS-28199-E1 8/29/02 9:16 AM Page 9
DESCRIPTION
Left view ............................................................................................2-1

Right view ..........................................................................................2-2
Controls and instruments ...................................................................2-3
2

5PS-28199-E1 8/29/02 9:16 AM Page 10
EAU00026
DESCRIPTION
Part locations
Left view 12 3 4 5 6 7 8
14 13 12 1110 9 9
1. Front fork spring preload adjusting bolt (page 3-15) 8. Grab bar
2. Front fork damping force adjusting 9. Luggage strap holders (page 3-18)
screw (page 3-15) 10. Seat lock (page 3-13)
3. Air filter element (page 6-16) 11. Shock absorber assembly rebound
4. Shock absorber assembly compression damping force adjusting knob (page 3-17)
damping force adjusting knob (page 3-17) 12. Shock absorber assembly spring
5. Battery (page 6-33) preload adjusting ring (page 3-16)
6. Fuses (page 6-34) 13. Shift pedal (page 3-9)
7. Storage compartment (page 3-14) 14. Engine oil drain bolt A (page 6-9)
2-1

5PS-28199-E1 8/29/02 9:16 AM Page 11
DESCRIPTION
Right view 9 15 9 16 17 18 19
24 23 22 21 20
15. Tool kit (page 6-1) 20. Engine oil filler cap (page 6-8)
16. Coolant reservoir (page 6-11) 21. Engine oil filter element (page 6-10)
17. Throttle stop screw (page 6-17) 22. Engine oil drain bolt B (page 6-10)
18. Front brake master cylinder (page 6-25) 23. Brake pedal (page 3-10)
19. Radiator cap (page 6-13) 24. Rear brake fluid reservoir (page 6-26)
2-2

5PS-28199-E1 8/29/02 9:16 AM Page 12
DESCRIPTION
Controls and instruments
1 2 345 6 7 8 9
1. Clutch lever (page 3-9) 6. Coolant temperature gauge (page 3-6)

2. Left handlebar switches (page 3-7) 7. Right handlebar switches (page 3-8)
3. Speedometer unit (page 3-4) 8. Brake lever (page 3-9)
4. Main switch/steering lock (page 3-1) 9. Throttle grip (page 6-18)
5. Tachometer unit (page 3-5)
2-3

5PS-28199-E1 8/29/02 9:16 AM Page 13
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ...................................................................3-1

Indicator and warning lights ...............................................................3-2
Speedometer unit ..............................................................................3-4
Tachometer unit .................................................................................3-5
Coolant temperature gauge ...............................................................3-6
Anti-theft alarm (optional) ..................................................................3-7 3
Handlebar switches ...........................................................................3-7
Clutch lever ........................................................................................3-9
Shift pedal ..........................................................................................3-9
Brake lever ........................................................................................3-9
Brake pedal .....................................................................................3-10
Fuel tank cap ...................................................................................3-10
Fuel ..................................................................................................3-11
Fuel tank breather hose ...................................................................3-12
Catalytic converter ...........................................................................3-12
Seat .................................................................................................3-13
Storage compartment ......................................................................3-14
Adjusting the front fork .....................................................................3-14
Adjusting the shock absorber assembly ..........................................3-16
Luggage strap holders .....................................................................3-18
Sidestand .........................................................................................3-18
Ignition circuit cut-off system ...........................................................3-19

5PS-28199-E1 8/29/02 9:16 AM Page 14
EAU00027
NOTE:
The headlight comes on automatical-
ly when the engine is started and
stays on until the key is turned to
“OFF”.
EAU00038
3 OFF
All electrical systems are off. The key
can be removed.
EAU00029 EAU00040
Main switch/steering lock

Main switch/steering lock
LOCK
The main switch/steering lock con- The steering is locked, and all electri-
trols the ignition and lighting systems, cal systems are off. The key can be
and is used to lock the steering. The removed.
various positions are described
below. To lock the steering
1. Turn the handlebars all the way
EAU04926 to the left.
ON 2. Push the key in from the “OFF”
All electrical circuits are supplied with position, and then turn it to
power; the meter lighting, taillight and “LOCK” while still pushing it.
auxiliary light come on, and the 3. Remove the key.
engine can be started. The key can-
not be removed. To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1

5PS-28199-E1 8/29/02 9:16 AM Page 15

EAU01590
a b . (Parking)
The steering is locked, and the tail-
light and auxiliary light are on, but all
other electrical systems are off. The
key can be removed.
The steering must be locked before
the key can be turned to “.”. 3
ECA00043
a. Push. cC 1. Fuel level warning symbol “ ”

b. Turn. 2. Left turn signal indicator light “4”
Do not use the parking position for
EW000016
an extended length of time, other- 3. High beam indicator light “&”
w 4. Neutral indicator light “N”
wise the battery may discharge.
5. Engine trouble indicator light “ ”
Never turn the key to “OFF” or
6. Right turn signal indicator light “6”
“LOCK” while the motorcycle is 7. Oil level warning light “7”
moving, otherwise the electrical EAU03034
systems will be switched off, Indicator and warning lights

which may result in loss of control
Indicator and warning lights
or an accident. Make sure that the EAU04478

motorcycle is stopped before turn- Fuel level warning symbol “ ”
ing the key to “OFF” or “LOCK”. Fuel level warning symbol
This fuel level warning symbol starts

flashing when the fuel level drops
below approximately 3.5 L.
3-2

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EAU00063 EAU04877
High beam indicator light “&” Oil level warning light “7”
High beam indicator light Oil level warning light
This indicator light comes on when This warning light comes on when
the high beam of the headlight is the engine oil level is low.
switched on. The electrical circuit of the warning
light can be checked by turning the
EAU00061
key to “ON”.
3 Neutral indicator light “N” If the warning light does not come on
Neutral indicator light
This indicator light comes on when for a few seconds, then go off, have a
1. Fuel level warning symbol “ ” the transmission is in the neutral Yamaha dealer check the electrical
2. Left turn signal indicator light “4”
position. circuit.
3. High beam indicator light “&”
4. Neutral indicator light “N”
5. Engine trouble indicator light “ ”
EAU04585 NOTE:
6. Right turn signal indicator light “6” Engine trouble warning light “ ” Even if the oil level is sufficient, the
Engine trouble warning light
7. Oil level warning light “7” This warning light comes on or flash- warning light may flicker when riding
EAU04121 es when an electrical circuit monitor- on a slope or during sudden acceler-
Turn signal indicator lights “4” ing the engine is defective. When this ation or deceleration, but this is not a
and “6” occurs, have a Yamaha dealer check malfunction.
Turn signal indicator lights
The corresponding indicator light the self-diagnosis system.

flashes when the turn signal switch is The electrical circuit of the warning
pushed to the left or right. light can be checked by turning the
key to “ON”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
3-3

5PS-28199-E1 8/29/02 9:16 AM Page 17

8 a fuel reserve tripmeter (which If the fuel level warning symbol flash-
shows the distance traveled on es (see page 3-2), the odometer dis-
the fuel reserve) play will automatically change to the
8 a fuel gauge fuel reserve tripmeter mode “TRIP F”
8 a self-diagnosis device and start counting the distance trav-
eled from that point. In that case,
NOTE: pushing the “SELECT” button switch-
Be sure to turn the key to “ON” es the display between the various 3
before using the “SELECT” and tripmeter and odometer modes in the
1. Speedometer “RESET” buttons.
2. Odometer/tripmeter following order:
3. “SELECT” button TRIP F → TRIP 1 → TRIP 2 → ODO
4. “RESET” button
5. Fuel gauge
Odometer and tripmeter modes → TRIP F
EAU04428
Pushing the “SELECT” button switch-
Speedometer unit es the display between the odometer To reset a tripmeter, select it by
Speedometer unit
mode “ODO” and the tripmeter pushing the “SELECT” button, and
The speedometer unit is equipped
modes “TRIP 1” and “TRIP 2” in the then push the “RESET” button. If you
with the following:
following order: do not reset the fuel reserve tripmeter
8 a digital speedometer (which
ODO → TRIP 1 → TRIP 2 → ODO manually, it will reset itself automati-
shows riding speed)
cally and the display will return to
8 an odometer (which shows the
“TRIP 1” after refueling and traveling
total distance traveled)
5 km.
8 two tripmeters (which show the
distance traveled since they
were last set to zero)
3-4

5PS-28199-E1 8/29/02 9:16 AM Page 18
NOTE: Self-diagnosis device

After resetting the fuel reserve trip- This model is equipped with a self-
meter, the display will return to diagnosis device for various electrical
“TRIP 1”, unless a different mode had circuits.
been previously selected; in that If any of those circuits are defective,
case, the display automatically the odometer/tripmeter will indicate a
returns to the prior mode. two-digit error code (e.g., 11, 12, 13).
3 If the odometer/tripmeter indicates
Fuel gauge such an error code, note the code
1. Tachometer
The fuel gauge indicates the amount number, and then have a Yamaha 2. Tachometer red zone
of fuel in the fuel tank. The display dealer check the motorcycle. 3. Clock
ECA00120 EAU04938
segments of the fuel gauge disap- cC Tachometer unit
pear towards “E” (Empty) as the fuel Tachometer unit
If the odometer/tripmeter indicates The electric tachometer allows the

level decreases. When only one seg-
an error code, the motorcycle rider to monitor the engine speed and
ment is left near “E”, refuel as soon
should be checked as soon as keep it within the ideal power range.
as possible.
possible in order to avoid engine When the key is turned to “ON”, the
damage. tachometer needle will move to
9,500 r/min and back to zero r/min in
order to test the electrical circuit.
3-5

5PS-28199-E1 8/29/02 9:16 AM Page 19

EC000003
cC NOTE:
8 After setting the clock, be sure to
Do not operate the engine in the
push the “SELECT” button
tachometer red zone.
before turning the key to “OFF”,
Red zone: 8,000 r/min and above
otherwise the clock will not be
set.
This tachometer unit is equipped with 8 When the key is turned to “OFF”,
a clock. the clock display will remain on 3
for 48 hours and then go off to 1. Coolant temperature gauge
To set the clock: prevent the battery from dis- 2. Coolant temperature red zone
1. Push both the “SELECT” and charging. EAU04939
“RESET” buttons for at least two Coolant temperature gauge

seconds.
Coolant temperature gauge
With the key in the “ON” position, the

2. When the hour digits start flash- coolant temperature gauge indicates
ing, push the “RESET” button to the temperature of the coolant. When
set the hours.
the key is turned to “ON”, the coolant
3. Push the “SELECT” button to temperature gauge needle will move
change the minutes. to “H” and back to “C” in order to test
4. When the minute digits start the electrical circuit. The coolant tem-
flashing, push the “RESET” but- perature varies with changes in the
ton to set the minutes. weather and engine load. If the nee-
5. Push the “SELECT” button to dle reaches or enters the red zone,
start the clock. stop the motorcycle and let the
engine cool. (See page 6-45 for fur-
ther instructions.)
3-6

5PS-28199-E1 8/29/02 9:16 AM Page 20

EC000002 EAU00109
cC Anti-theft alarm (optional)

Anti-theft alarm (optional)
Do not operate the engine if it is This motorcycle can be equipped

overheated. with an optional anti-theft alarm by a
Yamaha dealer. Contact a Yamaha
dealer for more information.
1. Pass switch “&”

2. Hazard switch “0”
3. Dimmer switch “&/%”
4. Turn signal switch “4/6”
5. Horn switch “*”
EAU00118
Handlebar switches
Handlebar switches
EAU00119
Pass switch “&”

Pass switch
Press this switch to flash the head-

light.
EAU03888
Dimmer switch “&/%”

Dimmer switch
Set this switch to “&” for the high

beam and to “%” for the low beam.
3-7

5PS-28199-E1 8/29/02 9:16 AM Page 21

EAU03889 EC000006
Turn signal switch “4/6” cC

Turn signal switch
To signal a right-hand turn, push this Do not use the hazard light for an
switch to “6”. To signal a left-hand extended length of time, otherwise
turn, push this switch to “4”. When the battery may discharge.
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after 3
it has returned to the center position.
1. Engine stop switch “#/$”
EAU00129
2. Start switch “,”
Horn switch “*” EAU03890
Horn switch
Press this switch to sound the horn. Engine stop switch “#/$”
Engine stop switch
EAU03826 Set this switch to “#” before starting

Hazard switch “0” the engine. Set this switch to “$” to
Hazard switch
With the key in the “ON” or “.” posi- stop the engine in case of an emer-
tion, use this switch to turn on the gency, such as when the motorcycle
hazard light (simultaneous flashing of overturns or when the throttle cable is
all turn signal lights). stuck.
EAU00143
The hazard light is used in case of an
emergency or to warn other drivers Start switch “,”
Start switch
when your motorcycle is stopped Push this switch to crank the engine
where it might be a traffic hazard. with the starter.
EC000005
cC
See page 5-1 for starting instruc-
tions prior to starting the engine.
3-8

5PS-28199-E1 8/29/02 9:16 AM Page 22
1. Clutch lever 1. Shift pedal 1. Brake lever

2. Brake lever position adjusting dial
EAU00152 EAU00157
3. Arrow mark
Clutch lever Shift pedal a. Distance between brake lever and
Clutch lever Shift pedal
handlebar grip
The clutch lever is located at the left The shift pedal is located on the left
EAU00161
handlebar grip. To disengage the side of the engine and is used in
Brake lever
clutch, pull the lever toward the han- combination with the clutch lever Brake lever
The brake lever is located at the right

dlebar grip. To engage the clutch, when shifting the gears of the
handlebar grip. To apply the front
release the lever. The lever should 6-speed constant-mesh transmission
brake, pull the lever toward the han-
be pulled rapidly and released slowly equipped on this motorcycle.
dlebar grip.
for smooth clutch operation.
The brake lever is equipped with a
The clutch lever is equipped with a
position adjusting dial.
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-19 for an explanation of the ignition
circuit cut-off system.)
3-9

5PS-28199-E1 8/29/02 9:16 AM Page 23

To adjust the distance between the
brake lever and the handlebar grip,
turn the adjusting dial while holding
the lever pushed away from the han- a
dlebar grip. Make sure that the
appropriate setting on the adjusting
dial is aligned with the arrow mark on 1
the brake lever. 3
1. Brake pedal 1. Fuel tank cap lock cover

a. Unlock.
EAU00162
EAU03232
Brake pedal
Brake pedal
Fuel tank cap
The brake pedal is on the right side Fuel tank cap
of the motorcycle. To apply the rear

To open the fuel tank cap
brake, press down on the brake
Open the fuel tank cap lock cover,
pedal.
insert the key into the lock, and then
turn it 1/8 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap

1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
3-10

5PS-28199-E1 8/29/02 9:16 AM Page 24

EAU00185
2. Turn the key counterclockwise to
2 1 cC
the original position, remove it,
and then close the lock cover. Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
NOTE: fuel may deteriorate painted sur-
The fuel tank cap cannot be closed faces or plastic parts.
unless the key is in the lock. In addi-
3 tion, the key cannot be removed if the EAU04284
cap is not properly closed and

1. Fuel tank filler tube Recommended fuel:
locked.
2. Fuel level REGULAR UNLEADED
EAU03753 GASOLINE ONLY
EWA00025
w Fuel
Fuel
Fuel tank capacity:
Make sure that there is sufficient fuel Total amount:
Make sure that the fuel tank cap is 20 L
in the tank. Fill the fuel tank to the
properly closed before riding. Reserve amount:
bottom of the filler tube as shown.
EW000130 3.5 L
w
8 Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8 Avoid spilling fuel on the hot
engine.
3-11

5PS-28199-E1 8/29/02 9:16 AM Page 25

ECA00104 EAU04960
cC Catalytic converter
Catalytic converter
Use only unleaded gasoline. The This motorcycle is equipped with a

use of leaded gasoline will cause catalytic converter in the muffler.
severe damage to internal engine
parts, such as the valves and pis- EW000128
ton rings, as well as to the exhaust w

system. The exhaust system is hot after 3
operation. Make sure that the
1. Fuel tank breather hose exhaust system has cooled down
Your Yamaha engine has been
designed to use regular unleaded EAU02955 before doing any maintenance
gasoline with a research octane num- Fuel tank breather hose
Fuel tank breather hose
work.
ber of 91 or higher. If knocking (or Before operating the motorcycle:
pinging) occurs, use a gasoline of a 8 Check the fuel tank breather
different brand or premium unleaded hose connection.
fuel. Use of unleaded fuel will extend 8 Check the fuel tank breather
spark plug life and reduce mainte- hose for cracks or damage, and
nance costs. replace it if damaged.
8 Make sure that the end of the
fuel tank breather hose is not
blocked, and clean it if neces-
sary.
3-12

5PS-28199-E1 8/29/02 9:16 AM Page 26

EC000114
cC a
The following precautions must be
observed to prevent a fire hazard
or other damages.
8 Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
1
3
the catalytic converter.
8 Never park the motorcycle 1. Seat lock 1. Projection (×2)
a. Unlock. 2. Seat holder (×2)
near possible fire hazards EAU02925
such as grass or other materi- To install the seat
Seat Insert the projections on the front of
als that easily burn.
8 Do not allow the engine to idle Seat the seat into the seat holder, push
To remove the seat the rear of the seat down to lock it in
too long.
Insert the key into the seat lock, turn place, and then remove the key.
it counterclockwise, and then pull the
seat off. NOTE:
Make sure that the seat is properly
secured before riding.
3-13

5PS-28199-E1 8/29/02 9:16 AM Page 27

EAU04929
When storing the owner’s manual or
other documents in the storage com- Adjusting the front fork
Front fork, adjusting
partment, be sure to wrap them in a This front fork is equipped with spring
plastic bag so that they will not get preload adjusting bolts and damping
wet. When washing the motorcycle, force adjusting screws.
be careful not to let any water enter
EW000035
the storage compartment.
w
3
Always adjust both fork legs
1. U-LOCK (optional) equally, otherwise poor handling
2. Strap
and loss of stability may result.
EAU04292
Storage compartment
Storage compartment
This storage compartment is

designed to hold an optional genuine
Yamaha U-LOCK. (Other locks may
not fit.) When placing a U-LOCK in
the storage compartment, securely
fasten it with the straps. When the U-
LOCK is not in the storage compart-
ment, be sure to secure the straps to
prevent losing them.
3-14

5PS-28199-E1 8/29/02 9:16 AM Page 28
b 1
2
1 4
3
a 6
5
1 7
2 8
3
1. Spring preload adjusting bolt 1. Standard setting 1. Damping force adjusting screw
2. Current setting
Spring preload 3. Front fork cap bolt Damping force
To increase the spring preload and 1. Turn the adjusting screw on each
NOTE:
thereby harden the suspension, turn fork leg in direction a until the
Align the appropriate groove on the
the adjusting bolt on each fork leg in screw moves almost a 1/2 turn
adjusting mechanism with the top of
direction a. To decrease the spring without clicking.
the front fork cap bolt.
preload and thereby soften the sus- 2. Continue turning the adjusting
pension, turn the adjusting bolt on screw in direction a until it
Setting
each fork leg in direction b. clicks. This is the minimum set-
Minimum (soft) 8
ting.
Standard 7
Maximum (hard) 1
3-15

5PS-28199-E1 8/29/02 9:16 AM Page 29

EAU04930
3. To increase the damping force,
continue turning the adjusting Adjusting the shock
screw in direction a. The third absorber assembly
Shock absorber assembly, adjusting
click after the minimum setting is This shock absorber assembly is

the maximum setting. If the equipped with a spring preload
adjusting screw is turned further adjusting ring and rebound and com-
in direction a, it will move half a pression damping force adjusting
turn before returning to the mini- knobs. 3
mum setting.
EC000015 1. Spring preload adjusting ring
NOTE: cC 2. Special wrench

3. Position indicator
Make sure that the adjusting screw is Never attempt to turn an adjusting
Spring preload
turned to one of the four settings. mechanism beyond the maximum
To increase the spring preload and
or minimum settings.
thereby harden the suspension, turn
Setting the adjusting ring in direction a. To
Minimum (soft) 1 decrease the spring preload and
Standard 2 thereby soften the suspension, turn
Maximum (hard) 4 the adjusting ring in direction b.
Setting
Minimum (soft) 1
Standard 5
Maximum (hard) 9
3-16

5PS-28199-E1 8/29/02 9:16 AM Page 30
NOTE:
Although the total number of clicks of
a damping force adjusting mecha-
nism may not exactly match the
above specifications due to small dif-
ferences in production, the actual
number of clicks always represents
3 the entire adjusting range. To obtain
1. Rebound damping force adjusting knob 1. Compression damping force adjusting
a precise adjustment, it would be
knob advisable to check the number of
Rebound damping force clicks of each damping force adjust-
Compression damping force
To increase the rebound damping ing mechanism and to modify the
To increase the compression damp-
force and thereby harden the specifications as necessary.
ing force and thereby harden the
rebound damping, turn the adjusting
compression damping, turn the
knob in direction a. To decrease the
adjusting knob in direction a. To
rebound damping force and thereby
decrease the compression damping
soften the rebound damping, turn the
force and thereby soften the com-
adjusting knob in direction b.
pression damping, turn the adjusting
Minimum (soft) 20 clicks in direction b* knob in direction b.
Standard 12 clicks in direction b*
Minimum (soft) 12 clicks in direction b*
Maximum (hard) 3 clicks in direction b*
Standard 11 clicks in direction b*
* With the adjusting knob fully turned in direction a
Maximum (hard) 1 clicks in direction b*
* With the adjusting knob fully turned in direction a
3-17

5PS-28199-E1 8/29/02 9:16 AM Page 31

EAU00315 EAU00330
w Sidestand
Sidestand
This shock absorber contains The sidestand is located on the left

highly pressurized nitrogen gas. side of the frame. Raise the side-
For proper handling, read and stand or lower it with your foot while
understand the following informa- holding the motorcycle upright.
tion before handling the shock
absorber. The manufacturer can- NOTE: 3
not be held responsible for proper- The built-in sidestand switch is part of
ty damage or personal injury that 1. Luggage strap holder (×4) the ignition circuit cut-off system,
may result from improper han- EAU00324 which cuts the ignition in certain situ-
dling. Luggage strap holders
Luggage strap holders
ations. (See further down for an
8 Do not tamper with or attempt There are four luggage strap holders explanation of the ignition circuit cut-
to open the gas cylinder. below the passenger seat, two of off system.)
8 Do not subject the shock which can be turned out for easier
absorber to an open flame or access.
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8 Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8 Always have a Yamaha dealer
service the shock absorber.
3-18

5PS-28199-E1 8/29/02 9:16 AM Page 32

EW000044 EAU03720 EW000045
w Ignition circuit cut-off w

The motorcycle must not be ridden system
Ignition circuit cut-of system
If a malfunction is noted, have a
with the sidestand down, or if the The ignition circuit cut-off system Yamaha dealer check the system
sidestand cannot be properly (comprising the sidestand switch, before riding.
moved up (or does not stay up), clutch switch and neutral switch) has
otherwise the sidestand could con- the following functions.
3 tact the ground and distract the 8 It prevents starting when the
operator, resulting in a possible transmission is in gear and the
loss of control. Yamaha’s ignition sidestand is up, but the clutch
circuit cut-off system has been lever is not pulled.
designed to assist the operator in 8 It prevents starting when the
fulfilling the responsibility of rais- transmission is in gear and the
ing the sidestand before starting clutch lever is pulled, but the
off. Therefore, check this system sidestand is still down.
regularly as described below and 8 It cuts the running engine when
have a Yamaha dealer repair it if it the transmission is in gear and
does not function properly. the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
3-19

5PS-28199-E1 8/29/02 9:16 AM Page 33
With the engine turned off: NOTE:

1. Move the sidestand down. This check is most reliable if performed with
2. Make sure that the engine stop switch is set to “#”. a warmed-up engine.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
YES NO The motorcycle should not be ridden until
3
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The clutch switch may be defective.
The system is OK. The motorcycle can be ridden.
3-20

5PS-28199-E1 8/29/02 9:16 AM Page 34

5PS-28199-E1 8/29/02 9:16 AM Page 35
PRE-OPERATION CHECKS
Pre-operation check list .....................................................................4-1

5PS-28199-E1 8/29/02 9:16 AM Page 36
EAU01114
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list

Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-10–3-12
• Check fuel line for leakage.
4 • Check oil level in engine.
Engine oil • If necessary, add recommended oil to specified level. 6-8–6-11
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-11–6-15
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake • Check fluid level in reservoir. 3-9–3-10, 6-24–6-26
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake • Check fluid level in reservoir. 3-10, 6-23–6-26
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Lubricate cable if necessary.
Clutch 3-9, 6-22–6-23
• Check lever free play.
• Adjust if necessary.
4-1

5PS-28199-E1 8/29/02 9:16 AM Page 37
ITEM CHECKS PAGE
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-18, 6-29
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Control cables 6-29
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
Drive chain 6-27–6-29
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires
• Check tire condition and tread depth.
6-18–6-22
4
• Check air pressure.
• Correct if necessary.
Brake and shift pedals 6-30
• Lubricate pedal pivoting points if necessary.
Brake and clutch levers 6-30
• Lubricate lever pivoting points if necessary.
Sidestand 6-30
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
3-2–3-3, 3-7–3-8, 6-35–6-38
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-18–3-20
• If system is defective, have Yamaha dealer check vehicle.
4-2

5PS-28199-E1 8/29/02 9:16 AM Page 38
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
very short time; and the added safety it assures is more than worth the time involved.
EWA00033
w
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the motorcycle.
4-3

5PS-28199-E1 8/29/02 9:16 AM Page 39
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine ............................................................................5-1

Shifting ...............................................................................................5-2
Recommended shift points (for Switzerland only) .............................5-3
Tips for reducing fuel consumption ....................................................5-3
Engine break-in .................................................................................5-3
Parking ..............................................................................................5-4

5PS-28199-E1 8/29/02 9:16 AM Page 40
EAU00372

EAU00373 EAU03951 ECA00083
w Starting the engine cC

Starting the engine
8 Become thoroughly familiar In order for the ignition circuit cut-off The oil level warning light and
with all operating controls and system to enable starting, one of the engine trouble warning light
their functions before riding. following conditions must be met: should come on for a few seconds,
Consult a Yamaha dealer 8 The transmission is in the neutral then go off. If a warning light does
regarding any control or func- position. not go off, see pages 3-2 and 3-3
tion that you do not thorough- 8 The transmission is in gear with for the corresponding warning
ly understand. the clutch lever pulled and the light circuit check.
8 Never start the engine or oper- sidestand up.
ate it in a closed area for any EW000054
2. Shift the transmission into the
length of time. Exhaust fumes w
5 neutral position.
are poisonous, and inhaling 8 Before starting the engine,
them can cause loss of con- check the function of the igni- NOTE:
sciousness and death within a tion circuit cut-off system When the transmission is in the neu-
short time. Always make sure according to the procedure tral position, the neutral indicator light
that there is adequate ventila- described on page 3-20. should be on, otherwise have a
tion. 8 Never ride with the sidestand Yamaha dealer check the electrical
8 Before starting out, make sure down. circuit.
that the sidestand is up. If the
sidestand is not raised com- 1. Turn the key to “ON” and make 3. Start the engine by pushing the
pletely, it could contact the sure that the engine stop switch start switch.
ground and distract the opera- is set to “#”.
tor, resulting in a possible loss
of control.
5-1

5PS-28199-E1 8/29/02 9:16 AM Page 41

EC000048
NOTE: cC
If the engine fails to start, release the
8 Even with the transmission in
start switch, wait a few seconds, and
the neutral position, do not
then try again. Each starting attempt
coast for long periods of time
should be as short as possible to pre-
with the engine off, and do not
serve the battery. Do not crank the
tow the motorcycle for long
engine more than 10 seconds on any
distances. The transmission is
one attempt.
properly lubricated only when
1. Shift pedal the engine is running.
ECA00045 N. Neutral position
cC EAU00423
Inadequate lubrication may
Shifting damage the transmission.
For maximum engine life, never 5
Shifting
8 Always use the clutch while
accelerate hard when the engine is Shifting gears lets you control the
changing gears to avoid dam-
cold! amount of engine power available for
aging the engine, transmis-
starting off, accelerating, climbing
sion, and drive train, which are
NOTE: hills, etc.
not designed to withstand the
The engine is warm when it quickly The gear positions are shown in the
shock of forced shifting.
responds to the throttle. illustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly
raise it.
5-2

5PS-28199-E1 8/29/02 9:16 AM Page 42

EAU02937 EAU04754 EAU01128
Recommended shift points Tips for reducing fuel Engine break-in

Engine break-in
(for Switzerland only)

Shift points (for Switzerland only)
consumption
Fuel consumption, tips for reducing
There is never a more important peri-
The recommended shift points during Fuel consumption depends largely on od in the life of your engine than the
acceleration are shown in the table your riding style. Consider the follow- period between 0 and 1,600 km. For
below. ing tips to reduce fuel consumption: this reason, you should read the fol-
Shift point 8 Shift up swiftly, and avoid high lowing material carefully.
(km/h) engine speeds during accelera- Since the engine is brand new, do
1st → 2nd 20 tion. not put an excessive load on it for the
2nd → 3rd 30
8 Do not rev the engine while shift- first 1,600 km. The various parts in
3rd → 4th 40
4th → 5th 50 ing down, and avoid high engine the engine wear and polish them-
5th → 6th 60 speeds with no load on the selves to the correct operating clear-
5
engine. ances. During this period, prolonged
NOTE: 8 Turn the engine off instead of let- full-throttle operation or any condition
When shifting down two gears at a ting it idle for an extended length that might result in engine overheat-
time, reduce the speed accordingly of time (e.g., in traffic jams, at ing must be avoided.
(e.g., down to 35 km/h when shifting traffic lights or at railroad cross-
from 5th to 3rd gear). ings).
5-3

5PS-28199-E1 8/29/02 9:16 AM Page 43

EAU04315 EAU00460
0–1,000 km Parking
Parking
Avoid prolonged operation above When parking, stop the engine, and
4,000 r/min. then remove the key from the main
switch.
1,000–1,600 km
Avoid prolonged operation above EW000058
6,000 r/min. w
ECA00058
8 Since the engine and exhaust
cC
system can become very hot,
After 1,000 km of operation, the park in a place where pedestri-
engine oil must be changed, and ans or children are not likely
the oil filter element replaced. 5
to touch them.
8 Do not park on a slope or on
1,600 km and beyond soft ground, otherwise the
The vehicle can now be operated motorcycle may overturn.
normally.
EC000053
cC
8 Keep the engine speed out of
the tachometer red zone.
8 If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
5-4

5PS-28199-E1 8/29/02 9:16 AM Page 44

5PS-28199-E1 8/29/02 9:16 AM Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .....................................................6-1 Checking and lubricating the brake and
Periodic maintenance and lubrication chart .........6-2 shift pedals ......................................................6-30
Removing and installing cowlings and panels ......6-5 Checking and lubricating the brake and
Checking the spark plugs .....................................6-7 clutch levers ....................................................6-30
Engine oil and oil filter element ............................6-8 Checking and lubricating the sidestand ..............6-30
Coolant ...............................................................6-11 Lubricating the rear suspension .........................6-31
Replacing the air filter element ...........................6-16 Checking the front fork .......................................6-31
Adjusting the engine idling speed .......................6-17 Checking the steering .........................................6-32
Adjusting the throttle cable free play ..................6-18 Checking the wheel bearings .............................6-32
Adjusting the valve clearance .............................6-18 Battery ................................................................6-33
Tires ...................................................................6-18 Replacing the fuses ............................................6-34
Cast wheels ........................................................6-22 Replacing a headlight bulb .................................6-35
Adjusting the clutch lever free play .....................6-22 Replacing a tail/brake light bulb .........................6-37 6
Adjusting the brake pedal position .....................6-23 Replacing a turn signal light bulb .......................6-37
Adjusting the rear brake light switch ...................6-24 Supporting the motorcycle ..................................6-38
Checking the front and rear brake pads .............6-24 Front wheel .........................................................6-39
Checking the brake fluid level ............................6-25 Rear wheel .........................................................6-40
Changing the brake fluid ....................................6-26 Troubleshooting ..................................................6-43
Drive chain slack ................................................6-27 Troubleshooting charts .......................................6-44
Lubricating the drive chain .................................6-28
Checking and lubricating the cables ...................6-29
Checking and lubricating the throttle grip
and cable .........................................................6-29

5PS-28199-E1 8/29/02 9:16 AM Page 46
EAU00462

EAU00464
NOTE:
Safety is an obligation of the owner.
If you do not have the tools or experi-
Periodic inspection, adjustment and
ence required for a particular job,
lubrication will keep your vehicle in
have a Yamaha dealer perform it for
the safest and most efficient condi-
you.
tion possible. The most important
points of inspection, adjustment, and
EW000063
lubrication are explained on the fol- w
lowing pages.
The intervals given in the periodic 1. Owner’s tool kit Modifications not approved by
maintenance and lubrication chart EAU01299
Yamaha may cause loss of perfor-
should be simply considered as a Owner’s tool kit mance and render the vehicle
general guide under normal riding
Tool kit
unsafe for use. Consult a Yamaha
The owner’s tool kit is located inside
conditions. However, DEPENDING dealer before attempting any
the storage compartment under the
6 ON THE WEATHER, TERRAIN, changes.
seat. (See page 3-13 for seat
GEOGRAPHICAL LOCATION, AND removal procedures.)
INDIVIDUAL USE, THE MAINTE- The service information included in
NANCE INTERVALS MAY NEED TO this manual and the tools provided in
BE SHORTENED. the owner’s tool kit are intended to
EW000060
assist you in the performance of pre-
w
ventive maintenance and minor
If you are not familiar with motor- repairs. However, additional tools
cycle maintenance work, have a such as a torque wrench may be nec-
Yamaha dealer do it for you. essary to perform certain mainte-
nance work correctly.
6-1

5PS-28199-E1 8/29/02 9:16 AM Page 47

EAU03685
Periodic maintenance and lubrication chart

Periodic maintenance and lubrication chart
NOTE:
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ODOMETER READING (× 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
• Check condition.
√ √
2 Spark plugs • Clean and regap.
• Replace. √ √
• Check valve clearance.
3 * Valves
• Adjust.
Every 40,000 km 6
4 Air filter element • Replace. √
5 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
6 * Front brake (See NOTE on page 6-4.)
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
7 * Rear brake (See NOTE on page 6-4.)
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. (See NOTE on page 6-4.) Every 4 years
9 * Wheels • Check runout and for damage. √ √ √ √
6-2

5PS-28199-E1 8/29/02 9:16 AM Page 48

1 10 20 30 40 CHECK
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check operation and for excessive play. √ √ √ √
12 * Swingarm
• Lubricate with lithium-soap-based grease. Every 50,000 km
• Check chain slack.
Every 1,000 km and after washing
13 Drive chain • Make sure that the rear wheel is properly aligned.
the motorcycle or riding in the rain
• Clean and lubricate.
• Check bearing play and steering for roughness. √ √ √ √ √
14 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20,000 km
15 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
6 16 Sidestand √ √ √ √ √
• Lubricate.
17 * Sidestand switch • Check operation. √ √ √ √ √ √
18 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber
19 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
Rear suspension relay • Check operation. √ √ √ √
20 * arm and connecting arm
pivoting points • Lubricate with lithium-soap-based grease. √ √
21 * Electronic fuel injection • Adjust engine idling speed and synchronization. √ √ √ √ √ √
6-3

5PS-28199-E1 8/29/02 9:16 AM Page 49

1 10 20 30 40 CHECK
• Change.
22 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
23 Engine oil filter element • Replace. √ √ √
• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
24 * Cooling system
• Change. Every 3 years
Front and rear brake
25 * • Check operation. √ √ √ √ √ √
switches
26 Moving parts and cables • Lubricate. √ √ √ √ √
• Check operation and free play.
Throttle grip housing
27 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
and cable
• Lubricate the throttle grip housing and cable.
• Check the air cut-off valve, reed valve, and hose for
28 * Air induction system damage. √ √ √ √ √
• Replace the entire air induction system if necessary.
29 * Muffler and exhaust pipe • Check the screw clamp for looseness. √ √ √ √ √ 6
Lights, signals and • Check operation.
30 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU03884
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
6-4

5PS-28199-E1 8/29/02 9:16 AM Page 50
1. Cowling A 1. Cowling B 1. Screw (×6)

2. Panel A 2. Panel B 2. Quick fastener
EAU01139 EAU04937
Removing and installing Cowlings A and B

cowlings and panels
Cowlings and panels, removing and instal ing
To remove one of the cowlings
6 The cowlings and panels shown Remove the cowling screws and the
above need to be removed to per- quick fastener, and then pull the
form some of the maintenance jobs cowling off as shown.
described in this chapter. Refer to
this section each time a cowling or NOTE:
panel needs to be removed and The quick fastener is removed by
installed. pushing the center pin in with a
screwdriver, and then pulling the fas-
tener out.
6-5

5PS-28199-E1 8/29/02 9:16 AM Page 51

After removal Before installation
1. Quick fastener 1. Screw 1. Panel B

2. Pin
EAU03317
To install the panel
To install the cowling Panels A and B 1. Place the panel in the original
Place the cowling in the original posi- To remove one of the panels position, and then install the
tion, and then install the screws and 1. Remove the corresponding cowl- screw.
the quick fastener. ing A or B. (See page 6-5 for 6
2. Install the seat and the cowling.
cowling removal and installation
NOTE: procedures.)
To install the quick fastener, push the 2. Remove the seat. (See page
center pin out so that it will protrude 3-13 for seat removal and instal-
from the fastener head, insert the fas- lation procedures.)
tener into the cowling, and then push 3. Remove the screw, and then
the protruding pin in until it is flush take the panel off.
with the fastener head.
6-6

5PS-28199-E1 8/29/02 9:16 AM Page 52

EAU01880
If a spark plug shows signs of elec-
Checking the spark plugs
Spark plugs, checking trode erosion and excessive carbon
The spark plugs are important engine or other deposits, it should be
components, which should be replaced.
checked periodically, preferably by a
Yamaha dealer. Since heat and Specified spark plug:
deposits will cause any spark plug to DPR8EA-9 (NGK) or
slowly erode, they should be X24EPR-U9 (DENSO)
removed and checked in accordance
with the periodic maintenance and a. Spark plug gap
Before installing a spark plug, the
lubrication chart. In addition, the con- spark plug gap should be measured Spark plug gap:
dition of the spark plugs can reveal with a wire thickness gauge and, if 0.8–0.9 mm
the condition of the engine. necessary, adjusted to specification.
The porcelain insulator around the Clean the surface of the spark plug
6 center electrode of each spark plug gasket and its mating surface, and
should be a medium-to-light tan (the then wipe off any grime from the
ideal color when the motorcycle is rid- spark plug threads.
den normally), and all spark plugs
installed in the engine should have Tightening torque:
the same color. If any spark plug Spark plug:
shows a distinctly different color, the 17.5 Nm (1.75 m·kgf)
engine could be defective. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the motorcycle.
6-7

5PS-28199-E1 8/29/02 9:16 AM Page 53

EAU04619
NOTE:
Engine oil and oil filter
If a torque wrench is not available
element
when installing a spark plug, a good Engine oil and oil filter element
The engine oil level should be

estimate of the correct torque is
checked before each ride. In addition,
1/4–1/2 turn past finger tight.
the oil must be changed and the oil
However, the spark plug should be
filter element replaced at the intervals
tightened to the specified torque as
specified in the periodic maintenance
soon as possible.
and lubrication chart.
1. Oil filler cap
To check the engine oil level 3. Wait a few minutes until the oil
1. Place the motorcycle on a level settles, remove the oil filler cap,
surface and hold it in an upright wipe the dipstick clean, insert it
position. back into the oil filler hole (with-
6
out screwing it in and with the
NOTE: arrow mark pointing upward as
Make sure that the motorcycle is shown), and then remove it
positioned straight up when checking again to check the oil level.
the oil level. A slight tilt to the side
can result in a false reading. NOTE:
The engine oil should be between the
2. Start the engine, warm it up for minimum and maximum level marks.
15 minutes, and then turn it off.
6-8

5PS-28199-E1 8/29/02 9:16 AM Page 54

EW000065
w
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil
cool down sufficiently before
removing the oil tank cap.
1. Oil filler cap 1. Engine oil drain bolt A
2. Dipstick
3. Maximum level mark 4. If the engine oil is below the min- To change the engine oil (with or
4. Minimum level mark
imum level mark, add sufficient without oil filter element replace-
EC000000
oil of the recommended type to ment)
cC
raise it to the correct level. 1. Start the engine, warm it up for
6 Do not operate the motorcycle 5. Install the oil filler cap. several minutes, and then turn it
until you know that the engine oil off.
level is sufficient. NOTE: 2. Place an oil pan under the
8 The engine oil tank is located engine to collect the used oil.
behind the cylinders. 3. Remove the engine oil filler cap
8 The engine oil should be and drain bolts to drain the oil
between the minimum and maxi- from the crankcase.
mum level marks.
NOTE:
Skip steps 4–6 if the oil filter element
is not being replaced.
6-9

5PS-28199-E1 8/29/02 9:16 AM Page 55

7. Install the engine oil drain bolts,
and then tighten them to the
specified torques.
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf)
Engine oil drain bolt B:
30 Nm (3.0 m·kgf)
1. Engine oil drain bolt B 1. Oil filter element
2. Oil filter element cover 2. O-ring (×2) 8. Add the specified amount of the
3. Bolt (×5) recommended engine oil, and
5. Remove and replace the oil filter
4. Remove the oil filter element then install and tighten the oil
element and O-rings.
cover by removing the bolts. filler cap.
6. Install the oil filter element cover
by installing the bolts, then tight- Recommended engine oil: 6
ening them to the specified See page 8-1.
torque. Oil quantity:
Tightening torque: Without oil filter element
Oil filter element cover bolt: replacement:
10 Nm (1.0 m·kgf) 3.8 L
With oil filter element
NOTE: replacement:
Make sure that the O-rings are prop- 3.9 L
erly seated. Total amount (dry engine):
4.7 L
6-10

5PS-28199-E1 8/29/02 9:16 AM Page 56

ECA00133 EAU04879
cC Coolant
Coolant
8 In order to prevent clutch slip- The coolant level should be checked

page (since the engine oil also before each ride. In addition, the
lubricates the clutch), do not coolant must be changed at the inter-
mix any chemical additives. vals specified in the periodic mainte-
Do not use oils with a diesel nance and lubrication chart.
specification of “CD” or oils of
a higher quality than specified. To check the coolant level
Checking
In addition, do not use oils 1. Coolant reservoir

1. Place the motorcycle on the cen- 2. Maximum level mark
labeled “ENERGY CONSERV- terstand. 3. Minimum level mark
ING II” or higher.
2. Check the coolant level in the
8 Make sure that no foreign NOTE:
coolant reservoir.
material enters the crankcase. 8 The coolant level must be
6 checked on a cold engine since NOTE:
9. Start the engine, and then let it the level varies with engine tem- The coolant should be between the
idle for several minutes while perature. minimum and maximum level marks.
checking it for oil leakage. If oil is 8 Make sure that the motorcycle is
leaking, immediately turn the positioned straight up when
engine off and check for the checking the coolant level. A
cause. slight tilt to the side can result in
10. Turn the engine off, and then a false reading.
check the oil level and correct it if
necessary.
6-11

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EC000080 EW000067
cC w
8 If coolant is not available, use Never attempt to remove the radia-
distilled water or soft tap water tor cap when the engine is hot.
instead. Do not use hard water
or salt water since it is harmful NOTE:
to the engine. 8 The radiator fan is automatically
8 If water has been used instead switched on or off according to
of coolant, replace it with the coolant temperature in the
1. Coolant reservoir cap coolant as soon as possible, radiator.
3. If the coolant is at or below the otherwise the engine may not 8 If the engine overheats, see
minimum level mark, remove be sufficiently cooled and the page 6-45 for further instructions.
panel B (See page 6-6 for panel cooling system will not be pro-
removal and installation proce- tected against frost and corro-
sion. 6
dures.), remove the reservoir
cap, add coolant to the maximum 8 If water has been added to the
level mark, and then install the coolant, have a Yamaha dealer
reservoir cap and the panel. check the antifreeze content of
the coolant as soon as possi-
Coolant reservoir capacity ble, otherwise the effective-
(up to the maximum level mark): ness of the coolant will be
0.25 L reduced.
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5PS-28199-E1 8/29/02 9:16 AM Page 58

EAU04461
To change the coolant

Changing
1. Place the motorcycle on a level

surface and let the engine cool if
necessary.
2. Remove the seat. (See page
3-13 for seat removal and instal- 1
1
lation procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowl- 1. Radiator cap retaining bolt 1. Coolant drain bolt (×2)
2. Radiator cap
ing and panel removal and instal- 7. Remove the coolant drain bolts
lation procedures.) 6. Remove the radiator cap retain-
to drain the cooling system.
4. Remove the fuel tank bolts, and ing bolt and the radiator cap.
EW000067
then lift the fuel tank to position it
6 w
away from the coolant reservoir.
(Do not disconnect the fuel Never attempt to remove the radia-
hoses!) tor cap when the engine is hot.
5. Place a container under the
engine to collect the used
coolant.
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5PS-28199-E1 8/29/02 9:16 AM Page 59

13. Install the coolant drain bolts,
Antifreeze/water mixture ratio:
and then tighten them to the
1:1
specified torque.
Recommended antifreeze:
High-quality ethylene glycol
NOTE:
antifreeze containing corrosion
Check the washers for damage and
inhibitors for aluminum engines
replace them if necessary.
Coolant quantity:
Total amount:
1. Bolt
Tightening torque: 1.7 L
2. Coolant reservoir Coolant drain bolt: Coolant reservoir capacity:
8. Remove the coolant reservoir 10 Nm (1.0 m·kgf) 0.25 L
bolt.
14. Pour the recommended coolant
9. Pull the coolant reservoir upward
into the radiator until it is full.
and away from the motorcycle. 6
10. Drain the remaining coolant from
the coolant reservoir by opening
the cap, then turning the reser-
voir upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
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EC000080 EWA00052
15. Install the radiator cap, start the
cC w
engine, let it idle for several min-
8 If coolant is not available, use utes, and then turn it off. 8 Before installing the fuel tank,
distilled water or soft tap water 16. Remove the radiator cap to make sure that the fuel hoses
instead. Do not use hard water check the coolant level in the are not damaged. If any fuel
or salt water since it is harmful radiator. If necessary, add suffi- hose is damaged, do not start
to the engine. cient coolant until it reaches the the engine but have a Yamaha
8 If water has been used instead top of the radiator, and then dealer replace the hose, other-
of coolant, replace it with install the radiator cap and the wise fuel may leak.
coolant as soon as possible, cap retaining bolt. 8 Make sure that the fuel hoses
otherwise the engine may not 17. Check the coolant level in the are properly connected and
be sufficiently cooled and the reservoir. If necessary, remove routed, and not pinched.
cooling system will not be pro- the coolant reservoir cap, add 8 Be sure to place the fuel tank
tected against frost and corro- coolant to the maximum level breather hose in the original
6 sion. position.
mark, and then install the cap.
8 If water has been added to the 18. Install the fuel tank.
coolant, have a Yamaha dealer 19. Install the panel, the cowling,
check the antifreeze content of and the seat.
the coolant as soon as possi- 20. Start the engine, and then check
ble, otherwise the effective- the vehicle for coolant leakage. If
ness of the coolant will be coolant is leaking, have a
reduced. Yamaha dealer check the cool-
ing system.
6-15

5PS-28199-E1 8/29/02 9:16 AM Page 61
1. Bolt (×2) 1. Air filter case cover 1. Air filter element

2. Screw (×8)
EAU04973
6. Insert a new air filter element into
Replacing the air filter 3. Remove the fuel tank bolts, and
the air filter case.
element then lift the fuel tank away from EC000082
cC
Air filter element, replacing
The air filter element should be the air filter case.

replaced at the intervals specified in 4. Remove the air filter case cover 6
8 Make sure that the air filter ele-
the periodic maintenance and lubrica- by removing the screws.
ment is properly seated in the
tion chart. Replace the air filter ele- 5. Pull the air filter element out.
air filter case.
ment more frequently if you are riding 8 The engine should never be
in unusually wet or dusty areas. operated without the air filter
1. Remove the seat. (See page element installed, otherwise
3-13 for seat removal and instal- the pistons and/or cylinders
lation procedures.) may become excessively
2. Remove cowlings A and B as worn.
well as panels A and B. (See
pages 6-5 and 6-6 for cowling
and panel removal and installa-
tion procedures.)
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5PS-28199-E1 8/29/02 9:16 AM Page 62

EAU04578
7. Install the air filter case cover by
installing the screws. Adjusting the engine idling
8. Place the fuel tank in the original speed
Engine idling speed
position and install the bolts. The engine idling speed must be
EWA00067 checked and, if necessary, adjusted
w as follows at the intervals specified in
8 Before installing the fuel tank, the periodic maintenance and lubrica-
make sure that the fuel hoses tion chart.
are not damaged. If any fuel The engine should be warm before
making this adjustment. 1. Throttle stop screw
hose is damaged, do not start
the engine but have a Yamaha Check the engine idling speed and, if
dealer replace the hose, other- NOTE: necessary, adjust it to specification
wise fuel may leak. The engine is warm when it quickly by turning the throttle stop screw. To
8 Make sure that the fuel hoses responds to the throttle. increase the engine idling speed, turn
6
are properly connected and the screw in direction a. To
routed, and not pinched. decrease the engine idling speed,
8 Be sure to place the fuel tank turn the screw in direction b.
breather hose and the fuel
tank overflow hose in the orig- Engine idling speed:
inal position. 1,100–1,200 r/min
NOTE:
9. Install the panels and cowlings. If the specified idling speed cannot
10. Install the seat. be obtained as described above,
have a Yamaha dealer make the
adjustment.
6-17

5PS-28199-E1 8/29/02 9:16 AM Page 63

EAU00637 EAU00658
Adjusting the valve Tires

Tires
clearance
Valve clearance, adjusting
To maximize the performance, dura-
The valve clearance changes with bility, and safe operation of your
use, resulting in improper air-fuel mix- motorcycle, note the following points
a ture and/or engine noise. To prevent regarding the specified tires.
this from occurring, the valve clear-
ance must be adjusted by a Yamaha Tire air pressure
dealer at the intervals specified in the The tire air pressure should be
a. Throttle cable free play periodic maintenance and lubrication checked and, if necessary, adjusted
EAU00635 chart. before each ride.
Adjusting the throttle cable EW000082
free play w
Throt le cable free play, adjusting
The throttle cable free play should 8 The tire air pressure must be
measure 3–5 mm at the throttle grip. checked and adjusted on cold 6
Periodically check the throttle cable tires (i.e., when the tempera-
free play and, if necessary, have a ture of the tires equals the
Yamaha dealer adjust it. ambient temperature).
8 The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
6-18

5PS-28199-E1 8/29/02 9:16 AM Page 64

Tire air pressure EWA00012
8 Adjust the suspension and tire
(measured on cold tires) w
air pressure with regard to the
Load* Front Rear
Because loading has an enormous load.
225 kPa 250 kPa
Up to 90 kg (2.25 kgf/cm2, (2.50 kgf/cm2, impact on the handling, braking, 8 Check the tire condition and
2.25 bar) 2.50 bar) performance and safety character- air pressure before each ride.
225 kPa 290 kPa istics of your motorcycle, you
90 kg–maximum (2.25 kgf/cm2, (2.90 kgf/cm2,
2.25 bar) 2.90 bar) should keep the following precau-
225 kPa 250 kPa tions in mind.
High-speed riding (2.25 kgf/cm2, (2.50 kgf/cm2, 8 NEVER OVERLOAD THE
2.25 bar) 2.50 bar)
MOTORCYCLE! Operation of
Maximum load* 203 kg an overloaded motorcycle may
* Total weight of rider, passenger, cargo and result in tire damage, loss of
accessories control, or severe injury. Make
sure that the total weight of
6 rider, passenger, cargo, and
accessories does not exceed
the specified maximum load
for the vehicle.
8 Do not carry along loosely
packed items, which can shift
during a ride.
8 Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
6-19

5PS-28199-E1 8/29/02 9:16 AM Page 65
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
EW000079
w
8 Have a Yamaha dealer replace
1. Tire sidewall excessively worn tires. 1. Tire air valve
a. Tire tread depth Besides being illegal, operat- 2. Valve core
3. Valve cap with seal
Tire inspection ing the motorcycle with exces-
The tires must be checked before sively worn tires decreases Tire information
each ride. If the center tread depth riding stability and can lead to This motorcycle is equipped with cast
reaches the specified limit, if the tire loss of control. wheels and tubeless tires with valves. 6
has a nail or glass fragments in it, or 8 The replacement of all wheel
if the sidewall is cracked, have a and brake related parts,
Yamaha dealer replace the tire imme- including the tires, should be
diately. left to a Yamaha dealer, who
has the necessary profession-
Minimum tire tread depth
1.6 mm al knowledge and experience.
(front and rear)
6-20

5PS-28199-E1 8/29/02 9:16 AM Page 66

EW000080 FRONT EAU00684
w Manufacturer Size Model w

8 The front and rear tires should Dunlop 120/70 ZR18 M/C (59W) D220FSTJ This motorcycle is fitted with
Metzeler 120/70 ZR18 M/C (59W) MEZ4 FRONT
be of the same make and super-high-speed tires. Note the
design, otherwise the handling REAR following points in order to make
characteristics of the motorcy- Manufacturer Size Model the most efficient use of these
cle cannot be guaranteed. Dunlop 160/60 ZR17 M/C (69W) D220STJ tires.
Metzeler 160/60 ZR17 M/C (69W) MEZ4
8 After extensive tests, only the 8 Use only the specified replace-
tires listed below have been ment tires. Other tires may run
FRONT & REAR
approved for this model by Tire air valve TR412
the danger of bursting at
Yamaha Motor Co., Ltd. Valve core #9000A (original) super high speeds.
8 Always make sure that the 8 Brand-new tires can have a
valve caps are securely relatively poor grip on certain
installed to prevent air pres- road surfaces until they have
6 sure leakage. been “broken in”. Therefore, it
8 Use only the tire valves and is advisable before doing any
valve cores listed below to high-speed riding to ride con-
avoid tire deflation during a servatively for approximately
high-speed ride. 100 km after installing a new
tire.
8 The tires must be warmed up
before a high-speed run.
8 Always adjust the tire air pres-
sure according to the operat-
ing conditions.
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5PS-28199-E1 8/29/02 9:16 AM Page 67

EAU03773
8 Ride at moderate speeds after
Cast wheels
Wheels changing a tire since the tire sur- c
To maximize the performance, dura- face must first be “broken in” for 2
bility, and safe operation of your 1
it to develop its optimal charac- a
motorcycle, note the following points teristics.
regarding the specified wheels.
8 The wheel rims should be b
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a 1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
Yamaha dealer replace the c. Clutch lever free play
wheel. Do not attempt even the EAU00694
smallest repair to the wheel. A Adjusting the clutch lever

deformed or cracked wheel must free play
be replaced.
Clutch lever free play, adjusting
6
The clutch lever free play should
8 The wheel should be balanced measure 10–15 mm as shown.
whenever either the tire or wheel Periodically check the clutch lever
has been changed or replaced. free play and, if necessary, adjust it
An unbalanced wheel can result as follows.
in poor performance, adverse 1. Loosen the locknut at the clutch
handling characteristics, and a lever.
shortened tire life. 2. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.
6-22

5PS-28199-E1 8/29/02 9:16 AM Page 68
1 2
2
1 b
a
1. Locknut (clutch lever) 1. Locknut (crankcase) a. Distance between brake pedal and footrest
2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut
EAU00712
3. If the specified clutch lever free 5. Loosen the locknut at the Adjusting the brake pedal
play could be obtained as crankcase. position
Brake pedal position, adjusting
described above, tighten the 6. To increase the clutch lever free The top of the brake pedal should be
6 locknut and skip the rest of the play, turn the adjusting nut in positioned approximately 32 mm
procedure, otherwise proceed as direction a. To decrease the below the top of the footrest as
follows. clutch lever free play, turn the shown. Periodically check the brake
4. Fully turn the adjusting bolt at the adjusting nut in direction b. pedal position and, if necessary,
clutch lever in direction a to 7. Tighten the locknut at the clutch have a Yamaha dealer adjust it.
loosen the clutch cable. lever and the crankcase.
6-23

5PS-28199-E1 8/29/02 9:16 AM Page 69

EW000109 EAU00721
w Checking the front and rear

A soft or spongy feeling in the brake pads
Front and rear brake pads, checking
brake pedal can indicate the pres- The front and rear brake pads must
ence of air in the hydraulic system. be checked for wear at the intervals
If there is air in the hydraulic sys- specified in the periodic maintenance
tem, have a Yamaha dealer bleed and lubrication chart.
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking 1. Brake light switch
2. Brake light switch adjusting nut
performance, which may result in
EAU00713
loss of control and an accident.
Adjusting the rear brake light
switch
Rear brake light switch, adjusting
The rear brake light switch, which is 6

activated by the brake pedal, is prop-
erly 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 ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
6-24

5PS-28199-E1 8/29/02 9:16 AM Page 70

Front brake Rear brake Front brake
1
1 1
1. Brake pad wear indicator groove 1. Lining thickness 1. Minimum level mark
EAU00725 EAU04510 EAU04856
Front brake pads Rear brake pads Checking the brake fluid
Each front brake pad is provided with Check each rear brake pad for dam- level
Brake fluid level, checking
a wear indicator groove, which allows age and measure the lining thick- Insufficient brake fluid may allow air
6 you to check the brake pad wear ness. If a brake pad is damaged or if to enter the brake system, possibly
without having to disassemble the the lining thickness is less than causing it to become ineffective.
brake. To check the brake pad wear, 0.8 mm, have a Yamaha dealer Before riding, check that the brake
check the wear indicator groove. If a replace the brake pads as a set. fluid is above the minimum level mark
brake pad has worn to the point that and replenish if necessary. A low
the wear indicator groove has almost brake fluid level may indicate worn
disappeared, have a Yamaha dealer brake pads and/or brake system
replace the brake pads as a set. leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
6-25

5PS-28199-E1 8/29/02 9:16 AM Page 71

Rear brake 8 Refill with the same type of brake EAU03985
fluid. Mixing fluids may result in a Changing the brake fluid

Brake fluid, changing
harmful chemical reaction and Have a Yamaha dealer change the

lead to poor braking perfor- brake fluid at the intervals specified in
1 mance. the NOTE after the periodic mainte-
8 Be careful that water does not nance and lubrication chart. In addi-
enter the brake fluid reservoir tion, have the oil seals of the brake
when refilling. Water will signifi- master cylinder and caliper as well as
cantly lower the boiling point of the brake hose replaced at the inter-
1. Minimum level mark vals listed below or whenever they
the fluid and may result in vapor
Observe these precautions: lock. are damaged or leaking.
8 When checking the fluid level, 8 Brake fluid may deteriorate paint- 8 Oil seals: Replace every two
make sure that the top of the ed surfaces or plastic parts. years.
brake fluid reservoir is level. Always clean up spilled fluid 8 Brake hose: Replace every four
years. 6
8 Use only the recommended qual- immediately.
ity brake fluid, otherwise the rub- 8 As the brake pads wear, it is nor-
ber seals may deteriorate, caus- mal for the brake fluid level to
ing leakage and poor braking gradually go down. However, if
performance. the brake fluid level goes down
suddenly, have a Yamaha dealer
Recommended brake fluid: check the cause.
DOT 4
6-26

5PS-28199-E1 8/29/02 9:16 AM Page 72

EAU00744
Drive chain slack

Drive chain slack
The drive chain slack should be

checked before each ride and adjust-
ed if necessary.
To check the drive chain slack

Checking
1. Place the motorcycle on a level

surface and hold it in an upright
a. Drive chain slack 1. Axle nut
position. 2. Drive chain slack adjusting bolt
2. Shift the transmission into the 3. Locknut
NOTE: 4. Alignment marks
neutral position.
EAU04372
When checking and adjusting the 3. Move the rear wheel by pushing
drive chain slack, the motorcycle To adjust the drive chain slack
the motorcycle to locate the tight- Adjusting
6 should be positioned straight up and 1. Loosen the axle nut, the brake
est portion of the drive chain,
there should be no weight on it. and then measure the drive caliper bracket bolt and the lock-
chain slack as shown. nut on each side of the
swingarm.
Drive chain slack: 2. To tighten the drive chain, turn
50–60 mm the adjusting bolt on each side of
4. If the drive chain slack is incor- the swingarm in direction a. To
rect, adjust it as follows. loosen the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction b, and
then push the rear wheel for-
ward.
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5PS-28199-E1 8/29/02 9:16 AM Page 73

EAU03006
3. Tighten the locknuts, and then
tighten the axle nut and the Lubricating the drive chain
Drive chain, lubricating
brake caliper bracket bolt to the The drive chain must be cleaned and
specified torques. lubricated at the intervals specified in
the periodic maintenance and lubrica-
Tightening torque: tion chart, otherwise it will quickly
Axle nut: wear out, especially when riding in
150 Nm (15.0 m·kgf) dusty or wet areas. Service the drive
Brake caliper bracket bolt: chain as follows.
1. Bolt 40 Nm (4.0 m·kgf) EC000097
2. Brake caliper bracket cC
NOTE: The drive chain must be lubricated
Using the alignment marks on each after washing the motorcycle or
side of the swingarm, make sure that riding in the rain.
both chain pullers are in the same 6
position for proper wheel alignment. 1. Clean the drive chain with
kerosene and a small soft brush.
EC000096 ECA00053
cC cC
Improper drive chain slack will To prevent damaging the O-rings,
overload the engine as well as do not clean the drive chain with
other vital parts of the motorcycle steam cleaners, high-pressure
and can lead to chain slippage or washers or inappropriate solvents.
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
6-28

5PS-28199-E1 8/29/02 9:16 AM Page 74

EAU02962 EAU04034
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive Checking and lubricating the Checking and lubricating the
chain with a special O-ring chain cables
Cables, checking and lubricating
throttle grip and cable
Throt le grip and cable, checking and lubricating
lubricant. The operation of all control cables The operation of the throttle grip
ECA00052 and the condition of the cables should be checked before each ride.
cC should be checked before each ride, In addition, the cable should be lubri-
Do not use engine oil or any other and the cables and cable ends cated or replaced at the intervals
lubricants for the drive chain, as should be lubricated if necessary. If a specified in the periodic maintenance
they may contain substances that cable is damaged or does not move chart.
could damage the O-rings. smoothly, have a Yamaha dealer
check or replace it.
Recommended lubricant:
Engine oil
6 EW000112
w
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
6-29

5PS-28199-E1 8/29/02 9:17 AM Page 75
EAU03370 EAU03164 EAU03165
Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals
Brake and shift pedals, checking and lubricating
brake and clutch levers
Brake and clutch levers, checking and lubricating
sidestand
Sidestand, checking and lubricating
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand
pedals should be checked before levers should be checked before should be checked before each ride, 6
each ride, and the pedal pivots each ride, and the lever pivots should and the sidestand pivot and metal-to-
should be lubricated if necessary. be lubricated if necessary. metal contact surfaces should be
lubricated if necessary.
Recommended lubricant: Recommended lubricant: EW000113
Lithium-soap-based grease Lithium-soap-based grease w

(all-purpose grease) (all-purpose grease) If the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Lithium-soap-based grease
(all-purpose grease)
6-30

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EAU02939
Checking the front fork

Front fork, checking
The condition and operation of the

front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition

EW000115
EAU04282
w
To check the operation
Lubricating the rear Securely support the motorcycle 1. Place the motorcycle on a level
suspension
Rear suspension, lubricating
so that there is no danger of it surface and hold it in an upright
The pivoting points of the rear sus- falling over. position.
6 pension must be lubricated at the 2. While applying the front brake,
intervals specified in the periodic Check the inner tubes for scratches, push down hard on the handle-
maintenance and lubrication chart. damage and excessive oil leakage. bars several times to check if the
front fork compresses and
rebounds smoothly.
Lithium-soap-based grease EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
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EAU00794 EAU01144
Checking the steering

Steering, checking
Checking the wheel bearings
Wheel bearings, checking
Worn or loose steering bearings may The front and rear wheel bearings
cause danger. Therefore, the opera- must be checked at the intervals
tion of the steering must be checked specified in the periodic maintenance
as follows at the intervals specified in and lubrication chart. If there is play
the periodic maintenance and lubrica- in the wheel hub or if the wheel does
tion chart. not turn smoothly, have a Yamaha
1. Place a stand under the engine dealer check the wheel bearings.
to raise the front wheel off the
ground. 2. Hold the lower ends of the front
EW000115
fork legs and try to move them
w
forward and backward. If any
Securely support the motorcycle free play can be felt, have a
so that there is no danger of it 6
Yamaha dealer check or repair
falling over. the steering.
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EAU00800 EW000116
8 Batteries produce explosive
Battery w
Battery hydrogen gas. Therefore, keep
This motorcycle is equipped with a 8 Electrolyte is poisonous and sparks, flames, cigarettes,
sealed-type (MF) battery, which does dangerous since it contains etc., away from the battery and
not require any maintenance. There sulfuric acid, which causes provide sufficient ventilation
is no need to check the electrolyte or severe burns. Avoid any con- when charging it in an
to add distilled water. tact with skin, eyes or clothing enclosed space.
EC000101
and always shield your eyes 8 KEEP THIS AND ALL BATTER-
cC when working near batteries. IES OUT OF THE REACH OF
Never attempt to remove the bat- In case of contact, administer CHILDREN.
tery cell seals, as this would per- the following FIRST AID.
manently damage the battery. 9 EXTERNAL: Flush with To charge the battery
plenty of water. Have a Yamaha dealer charge the
9 INTERNAL: Drink large battery as soon as possible if it
6 quantities of water or milk seems to have discharged. Keep in
and immediately call a mind that the battery tends to dis-
physician. charge more quickly if the motorcycle
9 EYES: Flush with water for is equipped with optional electrical
15 minutes and seek prompt accessories.
medical attention.
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5PS-28199-E1 8/29/02 9:17 AM Page 79

EC000102
To store the battery 7
cC
1. If the motorcycle will not be used
for more than one month, 8 Always keep the battery
7
remove the battery, fully charge charged. Storing a discharged
it, and then place it in a cool, dry battery can cause permanent
place. battery damage.
2. If the battery will be stored for 8 To charge a sealed-type (MF)
more than two months, check it battery, a special (constant-
12 34 56 8 9
at least once a month and fully voltage) battery charger is
required. Using a conventional 1. Odometer and clock fuse (backup fuse)
charge it if necessary. 2. Radiator fan fuse
3. Fully charge the battery before battery charger will damage 3. Turn signal light and hazard fuse
the battery. If you do not have 4. Ignition fuse
installation. 5. Signaling system fuse
4. After installation, make sure that access to a sealed-type (MF) 6. Headlight fuse
the battery leads are properly battery charger, have a 7. Spare fuse (×5)
Yamaha dealer charge your
8. Electronic fuel injection system fuse 6
connected to the battery termi- 9. Main fuse
nals. battery. EAU04880
Replacing the fuses

Fuses, replacing
The main fuse and the fuse box,

which contains the fuses for the indi-
vidual circuits, are located under the
seat. (See page 3-13 for seat
removal and installation procedures.)
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
6-34

5PS-28199-E1 8/29/02 9:17 AM Page 80

2. Remove the blown fuse, and 3. Turn the key to “ON” and turn on
then install a new fuse of the the electrical circuit in question to
specified amperage. check if the device operates.
4. If the fuse immediately blows
Specified fuses: again, have a Yamaha dealer
Main fuse: 40 A check the electrical system.
Headlight fuse: 15 A
Signaling system fuse: 10 A
Radiator fan fuse: 20 A
Ignition fuse: 10 A 1. Headlight bulb holder
2. Headlight coupler
Odometer and clock
EAU04503
fuse (backup fuse): 5A
Turn signal light and
Replacing a headlight bulb
Headlight bulb, replacing
hazard fuse: 10 A This motorcycle is equipped with

6 Electronic fuel quartz bulb headlights. If a headlight
injection fuse: 10 A bulb burns out, replace it as follows.
1. Disconnect the headlight cou-
EC000103 pler, and then remove the bulb
cC cover.
Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
6-35

5PS-28199-E1 8/29/02 9:17 AM Page 81

8 Headlight lens
9 Do not affix any type of tint-
ed film or stickers to the
headlight lens.
9 Do not use a headlight bulb
of a wattage higher than
a
specified.
1
4. Install the headlight bulb cover,
1. Headlight bulb holder a. Do not touch the glass part of the bulb.
and then connect the coupler.
EC000104
2. Unhook the headlight bulb hold- 5. Have a Yamaha dealer adjust
cC
er, and then remove the defec- the headlight beam if necessary.
tive bulb. Take care not to damage the fol-
EW000119 lowing parts:
w 8 Headlight bulb 6
Headlight bulbs get very hot. Do not touch the glass part of the
Therefore, keep flammable prod- headlight bulb to keep it free from
ucts away from a lit headlight bulb, oil, otherwise the transparency of
and do not touch the bulb until it the glass, the luminosity of the
has cooled down. bulb, and the bulb life will be
adversely affected. Thoroughly
3. Place a new headlight bulb into clean off any dirt and fingerprints
position, and then secure it with on the headlight bulb using a cloth
the bulb holder. moistened with alcohol or thinner.
6-36

5PS-28199-E1 8/29/02 9:17 AM Page 82

5. Install the socket (together with
the bulb) by turning it clockwise.
6. Install the seat.
1. Socket 1. Screw
2. Turn signal light lens
EAU04411
EAU03497
Replacing a tail/brake light
bulb Replacing a turn signal light
Tail/brake light bulb, replacing
bulb
1. Remove the seat. (See page Turn signal light bulb, replacing
6 1. Remove the turn signal light lens

3-13 for seat removal and instal-
by removing the screw.
lation procedures.)
2. Remove the defective bulb by
2. Remove the socket (together
pushing it in and turning it coun-
with the bulb) by turning it coun-
terclockwise.
terclockwise.
3. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
6-37

5PS-28199-E1 8/29/02 9:17 AM Page 83

EAU01579
To service the rear wheel
Supporting the motorcycle
Supporting the motorcycle Raise the rear wheel off the ground
Since this model is not equipped with by using a motorcycle stand or, if a
a centerstand, follow these precau- motorcycle stand is not available, by
tions when removing the front and placing a jack either under each side
rear wheel or performing other main- of the frame in front of the rear wheel
tenance requiring the motorcycle to or under each side of the swingarm.
stand upright. Check that the motor-
cycle is in a stable and level position
1. Turn signal light bulb before starting any maintenance. A
3. Insert a new bulb into the socket, strong wooden box can be placed
push it in, and then turn it clock- under the engine for added stability.
wise until it stops.
4. Install the lens by installing the To service the front wheel
1. Stabilize the rear of the motorcy- 6
screw.
ECA00065 cle by using a motorcycle stand
cC or, if an additional motorcycle
Do not overtighten the screw, oth- stand is not available, by placing
erwise the lens may break. a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
6-38

5PS-28199-E1 8/29/02 9:17 AM Page 84

ECA00046
cC
Do not apply the brake after the
1 2 brake calipers have been removed,
otherwise the brake pads will be
forced shut.
3
1. Wheel axle 1. Brake hose holder

2. Front wheel axle pinch bolt 2. Bolt (×2)
EAU01617
3. Brake caliper
Front wheel
Wheel (front)
2. Loosen the wheel axle with a
19-mm hexagon wrench.
6 To remove the front wheel 3. Lift the front wheel off the ground
Removing
EW000122 according to the procedure on

w page 6-38.
8 It is advisable to have a 4. Remove the brake hose holders
Yamaha dealer service the by removing the bolts.
wheel. 5. Remove the brake calipers by
8 Securely support the motorcy- removing the bolts.
cle so that there is no danger 6. Pull the wheel axle out, and then
of it falling over. remove the wheel.
1. Loosen the front wheel axle

pinch bolt, then the brake caliper
bolts.
6-39

5PS-28199-E1 8/29/02 9:17 AM Page 85

EAU04376
To install the front wheel Tightening torques:

Wheel axle:
Instal ing
1. Lift the wheel up between the

fork legs. 72 Nm (7.2 m·kgf)
2. Insert the wheel axle. Front wheel axle pinch bolt:
3. Lower the front wheel so that it is 20 Nm (2.0 m·kgf)
on the ground. Brake caliper bolt:
4. Install the brake calipers by 40 Nm (4.0 m·kgf)
installing the bolts.
7. Push down hard on the handle- 1. Bolt (×2)
bar several times to check for 2. Quick fastener (×3)
NOTE:
Make sure that there is enough proper fork operation. EAU04455
space between the brake pads

Rear wheel
before installing the brake calipers Wheel (rear)
onto the brake discs. To remove the rear wheel 6

Removing
EW000122
5. Install the brake hose holders by w

installing the bolts. 8 It is advisable to have a
6. Tighten the wheel axle, the front Yamaha dealer service the
wheel axle pinch bolt and the wheel.
brake caliper bolts to the speci- 8 Securely support the motorcy-
fied torques. cle so that there is no danger
of it falling over.
6-40

5PS-28199-E1 8/29/02 9:17 AM Page 86

1. Remove the drive chain cover by
removing the quick fasteners and
the bolts.
1. Axle nut 1. Bolt

2. Drive chain slack adjusting bolt 2. Brake caliper bracket
3. Locknut
4. Alignment marks 4. Remove the axle nut.
2. Loosen the axle nut and the 5. Loosen the locknut on each side
brake caliper bracket bolt. of the swingarm.
6 3. Lift the rear wheel off the ground 6. Turn the drive chain slack adjust-
according to the procedure on ing bolts fully in direction a.
page 6-38. 7. Push the wheel forward, tighten
the caliper bracket bolt, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.
6-41

5PS-28199-E1 8/29/02 9:17 AM Page 87

EAU04456
After removal Before installation
To install the rear wheel
Instal ing
1. Install the wheel by inserting the

wheel axle from the right hand
side.
NOTE:
Make sure that there is enough
space between the brake pads
before installing the wheel. 1. Quick fastener
2. Pin
8. Pull the wheel axle out, and then
remove the wheel. 2. Install the drive chain onto the Tightening torques:
ECA00119 rear sprocket. Axle nut:
cC 3. Loosen the brake caliper bracket 150 Nm (15.0 m·kgf)
bolt. Brake caliper bracket bolt: 6
Do not apply the brake after the
wheel has been removed together 4. Adjust the drive chain slack. 40 Nm (4.0 m·kgf)
with the brake disc, otherwise the (See page 6-27 for drive chain
slack adjustment procedures.) 7. Install the drive chain cover by
brake caliper pistons will be forced
5. Install the axle nut, and then installing the bolts and quick fas-
out.
lower the rear wheel so that it is teners.
on the ground. NOTE:
6. Tighten the axle nut and the To install a quick fastener, push the
brake caliper bracket bolt to the pin back so that it will protrude from
specified torques. the fastener head, and then insert the
fastener and push the protruding pin
in until it is flush with the fastener
head.
6-42

5PS-28199-E1 8/29/02 9:17 AM Page 88

EAU03087
Troubleshooting
Troubleshooting
Although Yamaha motorcycles

receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
6 cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
6-43

5PS-28199-E1 8/29/02 9:17 AM Page 89

EAU02990
Troubleshooting charts
Troubleshooting charts
Starting problems or poor engine performance

EW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
Operate the electric starter. 6
Have a Yamaha dealer
There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
4. Battery The engine turns over

The battery is good.
quickly. The engine does not start.
Operate the electric starter. Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-44

5PS-28199-E1 8/29/02 9:17 AM Page 90
Engine overheating
EW000070
w
8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8 After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
There is Have a Yamaha dealer check

The coolant level is low. leakage. and repair the cooling system.
Check the cooling system
for leakage.
There is
6 Add coolant. (See NOTE.)
Wait until the Check the coolant level in the no leakage.
engine has cooled. reservoir and radiator.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
6-45

5PS-28199-E1 8/29/02 9:17 AM Page 91
MOTORCYCLE CARE AND STORAGE
Care ...................................................................................................7-1
Storage ..............................................................................................7-4

5PS-28199-E1 8/29/02 9:17 AM Page 92
EAU04454

Before cleaning Cleaning
Care
Care
1. Cover the muffler outlets with ECA00010
While the open design of a motorcy- plastic bags after the engine has cC
cle reveals the attractiveness of the cooled down. 8 Avoid using strong acidic
technology, it also makes it more vul- 2. Make sure that all caps and cov- wheel cleaners, especially on
nerable. Rust and corrosion can ers as well as all electrical cou- spoked wheels. If such prod-
develop even if high-quality compo- plers and connectors, including ucts are used on hard-to-
nents are used. A rusty exhaust pipe the spark plug caps, are tightly remove dirt, do not leave the
may go unnoticed on a car, however, installed. cleaner on the affected area
it detracts from the overall appear- 3. Remove extremely stubborn dirt, any longer than instructed.
ance of a motorcycle. Frequent and like oil burnt onto the crankcase, Also, thoroughly rinse the area
proper care does not only comply with a degreasing agent and a off with water, immediately dry
with the terms of the warranty, but it brush, but never apply such it, and then apply a corrosion
will also keep your motorcycle looking products onto seals, gaskets, protection spray.
good, extend its life and optimize its sprockets, the drive chain and 8 Improper cleaning can damage
performance. wheel axles. Always rinse the dirt windshields, cowlings, panels
7 and degreaser off with water. and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
7-1

5PS-28199-E1 8/29/02 9:17 AM Page 93

8 Do not use any harsh chemical 8 For motorcycles equipped After normal use
products on plastic parts. Be with a windshield: Do not use Remove dirt with warm water, a mild
sure to avoid using cloths or strong cleaners or hard detergent, and a soft, clean sponge,
sponges which have been in sponges as they will cause and then rinse thoroughly with clean
contact with strong or abra- dulling or scratching. Some water. Use a toothbrush or bottle-
sive cleaning products, sol- cleaning compounds for plas- brush for hard-to-reach areas.
vent or thinner, fuel (gasoline), tic may leave scratches on the Stubborn dirt and insects will come
rust removers or inhibitors, windshield. Test the product off more easily if the area is covered
brake fluid, antifreeze or elec- on a small hidden part of the with a wet cloth for a few minutes
trolyte. windshield to make sure that it before cleaning.
8 Do not use high-pressure does not leave any marks. If
washers or steam-jet cleaners the windshield is scratched, After riding in the rain, near the sea
since they cause water seep- use a quality plastic polishing or on salt-sprayed roads
age and deterioration in the compound after washing. Since sea salt or salt sprayed on
following areas: seals (of roads during winter are extremely
wheel and swingarm bearings, corrosive in combination with water,
fork and brakes), electric com- carry out the following steps after 7
ponents (couplers, connec- each ride in the rain, near the sea or
tors, instruments, switches on salt-sprayed roads.
and lights), breather hoses
and vents. NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
7-2

5PS-28199-E1 8/29/02 9:17 AM Page 94

1. Clean the motorcycle with cold After cleaning 7. Wax all painted surfaces.
water and a mild detergent, after 1. Dry the motorcycle with a 8. Let the motorcycle dry complete-
the engine has cooled down. chamois or an absorbing cloth. ly before storing or covering it.
ECA00012
2. Immediately dry the drive chain EWA00001
cC and lubricate it to prevent it from w

Do not use warm water since it rusting. 8 Make sure that there is no oil
increases the corrosive action of 3. Use a chrome polish to shine or wax on the brakes or tires.
the salt. chrome, aluminum and stainless- If necessary, clean the brake
steel parts, including the exhaust discs and brake linings with a
2. After drying the motorcycle, system. (Even the thermally regular brake disc cleaner or
apply a corrosion protection induced discoloring of stainless- acetone, and wash the tires
spray on all metal, including steel exhaust systems can be with warm water and a mild
chrome- and nickel-plated, sur- removed through polishing.) detergent.
faces to prevent corrosion. 4. To prevent corrosion, it is recom- 8 Before operating the motorcy-
mended to apply a corrosion pro- cle test its braking perfor-
tection spray on all metal, includ- mance and cornering behav-
7 ing chrome- and nickel-plated, ior.
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7-3

5PS-28199-E1 8/29/02 9:17 AM Page 95

ECA00013
Storage Long-term
cC
Before storing your motorcycle for
8 Apply spray oil and wax spar- Storage
several months:
Short-term
ingly and make sure to wipe 1. Follow all the instructions in the
Always store your motorcycle in a
off any excess. “Care” section of this chapter.
cool, dry place and, if necessary, pro-
8 Never apply oil or wax to any 2. Fill up the fuel tank and add fuel
tect it against dust with a porous
rubber and plastic parts, but stabilizer (if available) to prevent
cover.
treat them with a suitable care ECA00014 the fuel tank from rusting and the
product. cC fuel from deteriorating.
8 Avoid using abrasive polish- 3. Perform the following steps to
8 Storing the motorcycle in a
ing compounds as they will protect the cylinders, piston
poorly ventilated room or cov-
wear away the paint. rings, etc. from corrosion.
ering it with a tarp, while it is
still wet, will allow water and a. Remove the spark plug caps
NOTE: and spark plugs.
humidity to seep in and cause
Consult a Yamaha dealer for advice b. Pour a teaspoonful of engine
rust.
on what products to use. oil into each spark plug bore.
8 To prevent corrosion, avoid
c. Install the spark plug caps 7
damp cellars, stables (because
of the presence of ammonia) onto the spark plugs, and then
and areas where strong chemi- place the spark plugs on the
cals are stored. cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
7-4

5PS-28199-E1 8/29/02 9:17 AM Page 96

d. Turn the engine over several 5. Check and, if necessary, correct NOTE:
times with the starter. (This the tire air pressure, and then lift Make any necessary repairs before
will coat the cylinder walls with the motorcycle so that both of its storing the motorcycle.
oil.) wheels are off the ground.
e. Remove the spark plug caps Alternatively, turn the wheels a
from the spark plugs, and then little every month in order to pre-
install the spark plugs and the vent the tires from becoming
spark plug caps. degraded in one spot.
EWA00003
6. Cover the muffler outlets with
w plastic bags to prevent moisture
To prevent damage or injury from from entering them.
sparking, make sure to ground the 7. Remove the battery and fully
spark plug electrodes while turn- charge it. Store it in a cool, dry
ing the engine over. place and charge it once a
month. Do not store the battery
4. Lubricate all control cables and in an excessively cold or warm
7 place [less than 0 °C or more
the pivoting points of all levers
and pedals as well as of the than 30 °C]. For more informa-
sidestand/centerstand. tion on storing the battery, see
page 6-34.
7-5

5PS-28199-E1 8/29/02 9:17 AM Page 97
SPECIFICATIONS
Specifications ....................................................................................8-1
Conversion table ................................................................................8-5

5PS-28199-E1 8/29/02 9:17 AM Page 98
EAU01038
SPECIFICATIONS
Specifications
Specifications
Model TDM900 Engine oil

Dimensions Type
Overall length 2,180 mm
Overall width 800 mm
Overall height 1,290 mm
Seat height 825 mm
Wheelbase 1,485 mm
Ground clearance 160 mm
Recommended engine oil
Minimum turning radius 2,900 mm classification API Service SE, SF, SG type
Basic weight (with oil and full or higher
fuel tank) 221 kg
cC
Engine
In order to prevent clutch slippage (since the engine oil also
Engine type Liquid-cooled 4-stroke, DOHC lubricates the clutch), do not mix any chemical additives. Do
Cylinder arrangement Forward-inclined parallel not use oils with a diesel specification of “CD” or oils of a
2-cylinder higher quality than specified. In addition, do not use oils
Displacement 897 cm3 labeled “ENERGY CONSERVING II” or higher.
8
Bore × Stroke 92.0 × 67.5 mm
Capacity
Compression ratio 10.4:1
Without oil filter element
Starting system Electric starter
removal 3.8 L
Lubrication system Dry sump
With oil filter element removal 3.9 L
Total amount (dry engine) 4.7 L
8-1

5PS-28199-E1 8/29/02 9:17 AM Page 99
SPECIFICATIONS
Cooling system capacity Operation Left foot

(total amount) 1.7 L
Gear ratio 1st 2.750
Air filter Oil-coated paper element
2nd 1.947
Fuel
3rd 1.545
Type REGULAR UNLEADED
4th 1.240
GASOLINE ONLY
5th 1.040
Fuel tank capacity 20 L
6th 0.923
Fuel reserve amount 3.5 L
Spark plug Chassis
Frame type Diamond
Manufacturer/model NGK/DPR8EA-9 or
DENSO/X24EPR-U9 Caster angle 25.5°
Gap 0.8–0.9 mm Trail 114 mm
Clutch type Wet, multiple-disc Tires

Transmission Front
Primary reduction system Spur gear Type Tubeless tire
Primary reduction ratio 1.718 Size 120/70 ZR18 M/C (59W)

Manufacturer/ Dunlop/D220FSTJ 8
Secondary reduction system Chain drive
model Metzeler/MEZ4 FRONT
Secondary reduction ratio 2.625
Rear
Number of drive chain
sprocket teeth (front/rear) 16/42 Type Tubeless tire
Transmission type Constant mesh 6-speed Size 160/60 ZR17 M/C (69W)
Manufacturer/ Dunlop/D220STJ
model Metzeler/MEZ4
8-2

5PS-28199-E1 8/29/02 9:17 AM Page 100
SPECIFICATIONS
Maximum load* 203 kg Brakes

Tire air pressure Front
(measured on cold tires) Type Dual disc brake
Up to 90 kg* Operation Right hand
Front 225 kPa (2.25 kgf/cm2, 2.25 bar)
Fluid DOT 4
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear
90 kg load–Maximum*
Type Single disc brake
Operation Right foot
Fluid DOT 4
High-speed riding
Suspension
Front
Type Telescopic fork
*Total weight of rider, passenger, cargo and accessories
Rear
Wheels
Type Swingarm (link suspension)
Front
Spring/shock absorber
Type Cast wheel
8 Front Coil spring/oil damper
Size 18 M/C × MT 3.50
Rear Coil spring/gas-oil damper
Rear
Wheel travel
Type Cast wheel
Front 150 mm
Size 17 M/C × MT 5.00
Rear 133 mm
8-3

5PS-28199-E1 8/29/02 9:17 AM Page 101
SPECIFICATIONS
Electrical system Fuses

Ignition system T.C.I. (digital) Main fuse 40 A
Charging system Headlight fuse 15 A
Type A.C. magneto Signaling system fuse 10 A
Standard output 14 V, 31.5 A @ 5,000 r/min Ignition fuse 10 A
Battery Turn signal light and hazard
fuse 10 A
Type GT12B-4
Odometer and clock fuse
Voltage, capacity 12 V, 10 Ah
(backup fuse) 5A
Headlight bulb type Halogen
Radiator fan fuse 20 A
Bulb voltage, wattage × quantity
Electronic fuel injection
Headlight 12 V, 55 W × 2 system fuse 10 A
Auxiliary light 12 V, 5 W × 1
Tail/brake light 12 V, 5/21 W × 1
Front turn signal light 12 V, 10 W × 2
Rear turn signal light 12 V, 10 W × 2
8
Meter lighting 12 V, 2 W × 2
Neutral indicator light 12 V, 1.2 W × 1
High beam indicator light 12 V, 1.4 W × 1
Turn signal indicator light 12 V, 1.2 W × 2
Oil level warning light L.E.D. × 1
Engine trouble warning light 12 V, 1.4 W × 1
8-4

5PS-28199-E1 8/29/02 9:17 AM Page 102
SPECIFICATIONS
EAU04513
Conversion table Conversion table

Conversion table
METRIC SYSTEM TO IMPERIAL SYSTEM
All specification data in this manual are listed in SI and
Metric unit Conversion factor Imperial unit
METRIC UNITS.
m·kgf × 7.233 ft·lbf
Torque
m·kgf × 86.794 in·lbf
cm·kgf × 0.0723 ft·lbf
Use this table to convert METRIC unit values to IMPERIAL cm·kgf × 0.8679 in·lbf
unit values. kg × 2.205 lb
Weight
g × 0.03527 oz
Example: Speed km/h × 0.6214 mi/h

km × 0.6214 mi
METRIC VALUE CONVERSION IMPERIAL VALUE m × 3.281 ft
Distance m × 1.094 yd
FACTOR cm × 0.3937 in
mm × 0.03937 in
2 mm × 0.03937 = 0.08 in
cc (cm3) × 0.03527 oz (IMP liq.)
Volume, cc (cm3) × 0.06102 cu·in
Capacity L (liter) × 0.8799 qt (IMP liq.)
L (liter) × 0.2199 gal (IMP liq.)
kg/mm × 55.997 lb/in
Miscellaneous kgf/cm2 × 14.2234 psi (lbf/in2)
°C × 1.8 + 32 °F
8-5

5PS-28199-E1 8/29/02 9:17 AM Page 103
CONSUMER INFORMATION
Identification numbers .......................................................................9-1

Key identification number ..................................................................9-1
Vehicle identification number .............................................................9-1
Model label ........................................................................................9-2

5PS-28199-E1 8/29/02 9:17 AM Page 104
EAU01039
EAU02944
Identification numbers
Identification numbers
Record the key identification number,

vehicle identification number and
model label information in the spaces
provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
1. KEY IDENTIFICATION 1. Key identification number 1. Identification number
NUMBER: EAU01041 EAU01043
Key identification number Vehicle identification number

Vehicle identification number
Key identification number
The key identification number is The vehicle identification number is

stamped into the key tag. stamped into the steering head pipe.
2. VEHICLE IDENTIFICATION Record this number in the space pro- Record this number in the space pro-
NUMBER: vided and use it for reference when vided.
ordering a new key.
NOTE:
The vehicle identification number is
3. MODEL LABEL INFORMATION: used to identify your motorcycle and
may be used to register your motor-
9 1
cycle with the licensing authority in
6 your area.
9-1

5PS-28199-E1 8/29/02 9:17 AM Page 105
1. Model label
EAU01050
Model label
Model label
The model label is affixed to the

frame under the seat. (See page 3-13
for seat removal and installation pro-
cedures.) Record the information on
this label in the space provided. This
information will be needed when
ordering spare parts from a Yamaha
dealer.
9
9-2

5PS-28199-E1 8/29/02 9:17 AM Page 106
INDEX
A Checking ............................................6-27 Indicator and warning lights ....................3-2

Air filter element, replacing ...................6-16 Drive chain, lubricating .........................6-28 Fuel level warning symbol ...................3-2
Anti-theft alarm (optional) .......................3-7 Turn signal indicator lights ...................3-3
E High beam indicator light .....................3-3
B Engine break-in ......................................5-3 Neutral indicator light ...........................3-3
Battery ..................................................6-33 Engine idling speed ..............................6-17 Engine trouble warning light ................3-3
Brake and clutch levers, checking Engine oil and oil filter element ..............6-8 Oil level warning light ...........................3-3
and lubricating ...................................6-30
Brake and shift pedals, checking F K
and lubricating ...................................6-30 Front and rear brake pads, checking ....6-24 Key identification number .......................9-1
Brake fluid level, checking ....................6-25 Front fork, adjusting ..............................3-14
Brake fluid, changing ............................6-26 Front fork, checking ..............................6-31 L
Brake lever .............................................3-9 Fuel ......................................................3-11 Luggage strap holders ..........................3-18
Brake pedal ..........................................3-10 Fuel consumption, tips for reducing .......5-3
Brake pedal position, adjusting ............6-23 Fuel tank breather hose .......................3-12 M
Fuel tank cap ........................................3-10 Main switch/steering lock .......................3-1
C Fuses, replacing ...................................6-34 Model label .............................................9-2
Cables, checking and lubricating ..........6-29
Care ........................................................7-1 H P
Catalytic converter ................................3-12 Handlebar switches ................................3-7 Parking ...................................................5-4
Clutch lever ............................................3-9 Dimmer switch .....................................3-7 Part locations ..........................................2-1
Clutch lever free play, adjusting ...........6-22 Engine stop switch ...............................3-8 Periodic maintenance and lubrication
Conversion table ....................................8-5 Hazard switch ......................................3-8 chart .....................................................6-2
Coolant .................................................6-11 Horn switch ..........................................3-8 Pre-operation check list ..........................4-1
Checking ............................................6-11 Pass switch ..........................................3-7
Changing ...........................................6-13 Start switch ..........................................3-8 R
Coolant temperature gauge ....................3-6 Turn signal switch ................................3-8 Rear brake light switch, adjusting .........6-24
Cowlings and panels, removing Headlight bulb, replacing ......................6-35 Rear suspension, lubricating ................6-31
and installing ........................................6-5
I S
D Identification numbers ............................9-1 Seat ......................................................3-13
Drive chain slack ..................................6-27 Ignition circuit cut-off system ................3-19 Shift pedal ..............................................3-9
Adjusting ............................................6-27

5PS-28199-E1 8/29/02 9:17 AM Page 107
INDEX
Shift points (for Switzerland only) ...........5-3 W

Shifting ...................................................5-2 Wheel (front)..........................................6-39
Shock absorber assembly, adjusting ....3-16 Installing .............................................6-40
Sidestand .............................................3-18 Removing ...........................................6-39
Sidestand, checking and lubricating .....6-30 Wheel (rear) .........................................6-40
Spark plugs, checking ............................6-7 Installing .............................................6-42
Specifications .........................................8-1 Removing ...........................................6-40
Speedometer unit ...................................3-4 Wheel bearings, checking ....................6-32
Starting the engine .................................5-1 Wheels .................................................6-22
Steering, checking ................................6-32
Storage ...................................................7-4
Storage compartment ...........................3-14
Supporting the motorcycle ....................6-38
T
Tachometer unit .....................................3-5
Tail/brake light bulb, replacing ..............6-37
Throttle cable free play, adjusting ........6-18
Throttle grip and cable, checking
and lubricating ...................................6-29
Tires .....................................................6-18
Tool kit ....................................................6-1
Troubleshooting ....................................6-43
Troubleshooting charts .........................6-44
Turn signal light bulb, replacing ............6-37
V
Valve clearance, adjusting ...................6-18
Vehicle identification number .................9-1

5PS-28199-E1 8/29/02 9:17 AM Page 108

5PS-E1_hyoushi 8/29/02 8:44 AM Page 1
YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2002.9-0.5x1 !
(E)

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OWNER’S MANUAL

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Welcome to the Yamaha world of motorcycling!

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IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death

cC A CAUTION indicates special precautions that must be taken to avoid damage

NOTE: A NOTE provides key information to make procedures easier or clearer.

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IMPORTANT MANUAL INFORMATION

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1 GIVE SAFETY THE RIGHT OF WAY 1

3 INSTRUMENT AND CONTROL FUNCTIONS 3

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

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GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY ...............................................1-1

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QGIVE SAFETY THE RIGHT OF WAY

Enjoy your ride!

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Left view ............................................................................................2-1

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1. Clutch lever (page 3-9) 6. Coolant temperature gauge (page 3-6)

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INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock ...................................................................3-1

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INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock

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INSTRUMENT AND CONTROL FUNCTIONS

a. Push. cC 1. Fuel level warning symbol “ ”

systems will be switched off, Indicator and warning lights

or an accident. Make sure that the EAU04478

This fuel level warning symbol starts

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INSTRUMENT AND CONTROL FUNCTIONS

The corresponding indicator light the self-diagnosis system.

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INSTRUMENT AND CONTROL FUNCTIONS

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INSTRUMENT AND CONTROL FUNCTIONS

NOTE: Self-diagnosis device

If the odometer/tripmeter indicates The electric tachometer allows the

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INSTRUMENT AND CONTROL FUNCTIONS

“RESET” buttons for at least two Coolant temperature gauge

With the key in the “ON” position, the

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INSTRUMENT AND CONTROL FUNCTIONS

cC Anti-theft alarm (optional)

Do not operate the engine if it is This motorcycle can be equipped

1. Pass switch “&”

Pass switch “&”

Press this switch to flash the head-

Dimmer switch “&/%”