Yamaha XV1600A (2002) User Manual

XV1600A

OWNER’S MANUAL

EAU03338

INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of a Yamaha Wild Star™, you are benefiting from Yamaha’s vast expe­rience and newest technology 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 Yamaha Wild Star’s. The owner’s manual does not only instruct you in how to
operate, inspect and maintain your motorcycle, 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!

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 IS
INVOLVED!

EAU00005

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the
motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

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

NOTE:

@

This manual should be considered a permanent part of this motorcycle and should remain

●

with it even if the motorcycle is subsequently sold.
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 questions concerning this manual, please consult your Yamaha dealer.

@

IMPORTANT MANUAL INFORMATION

EW000002

WARNING

@

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

@

IMPORTANT MANUAL INFORMATION

XV1600A

OWNER’S MANUAL

© 2001 by Yamaha Motor Co., Ltd.

1st edition, May 2001

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan.

EAU04229

TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY

2 DESCRIPTION

3 INSTRUMENT AND CONTROL FUNCTIONS

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTANT RIDING POINTS

6 PERIODIC MAINTENANCE AND MINOR REPAIR

7 MOTORCYCLE CARE AND STORAGE

8 SPECIFICATIONS

9 CONSUMER INFORMATION

INDEX

1

2

3

4

5

6

7

8

9

GIVE SAFETY THE RIGHT OF WAY

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

1

1-

GIVE SAFETY THE RIGHT OF WAY

EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. 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
passengers. 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 protective 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 defensively—avoiding all dangers, including those caused by others.

Enjoy your ride!

1-1

DESCRIPTION

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

Right view........................................................................................... 2-2

Controls and instruments ................................................................... 2-3

2

2-

DESCRIPTION

Left view

2

EAU00026

1. Engine oil drain bolt (crankcase) (page 6-10)

2. Shift pedal (page 3-7)

3. Starter (choke) knob (page 3-12)

4. Fuel cock (page 3-11)

5. Rider seat (page 3-12)

6. Owner’s tool kit (page 6-1)

7. Helmet holder (page 3-13)

8. Rear turn signal lights (page 6-38)

9. Tail/brake light (page 6-38)

10. Fuses (page 6-35)

2-1

Right view

DESCRIPTION

2

11. Passenger footrest

12. Passenger seat

13. Engine oil filler cap (page 6-8)

14. Fuel tank (page 3-9)

15. Fuel tank cap (page 3-9)

16. Headlight (page 6-36)

17. Front turn signal lights (page 6-38)

18. Throttle stop screw (page 6-16)

19. Brake pedal (page 3-8)

20. Engine oil filter cartridge (page 6-10)

21. Rider footrest

22. Engine oil drain bolt (oil tank) (page 6-9)

23. Transfer case oil drain bolt (page 6-12)

24. Shock absorber assembly spring
preload adjusting nut (page 3-14)

25. Muffler

2-2

DESCRIPTION

Controls and instruments

2

1. Clutch lever (page 3-7)

2. Left handlebar switches (page 3-6)

3. Speedometer unit (page 3-3)

4. Main switch/steering lock (page 3-1)

5. Right handlebar switches (page 3-6)

6. Throttle grip (page 6-17)

7. Brake lever (page 3-8)

2-3

INSTRUMENT AND CONTROL FUNCTIONS

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

Indicator and warning lights ................................3-2

Speedometer unit ................................................3-3

Self-diagnosis device ...........................................3-4

Fuel gauge ........................................................... 3-4

Anti-theft alarm (optional) .................................... 3-4

Clock .................................................................... 3-5

Handlebar switches ............................................. 3-6

Clutch lever .......................................................... 3-7

Shift pedal ............................................................ 3-7

Brake lever ........................................................... 3-8

Brake pedal .......................................................... 3-8

Fuel tank cap ...................................................... 3-9

Fuel ..................................................................... 3-9

Fuel tank breather hose .................................... 3-10

Fuel cock ........................................................... 3-11

Starter (choke) knob ......................................... 3-12

Locking the steering with a padlock .................. 3-12

Rider seat .......................................................... 3-12

Helmet holder .................................................... 3-13

Adjusting the shock absorber assembly ............ 3-14

Sidestand .......................................................... 3-15

Ignition circuit cut-off system ............................. 3-16

3

3-

WARNING

INSTRUMENT AND CONTROL FUNCTIONS

3

EAU00029

Main switch/steering lock

The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various

LOCK

The steering is locked, and all electrical
systems are off. The key can be re­moved.

positions are described below.

To lock the steering

EAU00036

ON

All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.

EAU00038

1. Turn the handlebars all the way to
the left.

2. Push the key in from the “OFF” po­sition, and then turn it to “LOCK”
while still pushing it.

3. Remove the key.

OFF

All electrical systems are off. The key
can be removed.

To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.

EAU00040

EAU00027

1. Push.

2. Turn.

EW000016

@

Never turn the key to “OFF” or
“LOCK” while the motorcycle is

moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor­cycle is stopped before turning the
key to “OFF” or “LOCK”.

@

3-1

INSTRUMENT AND CONTROL FUNCTIONS

EAU01590

(Parking)

The steering is locked, and the taillight
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 “”.

ECA00043

CAUTION:

@

Do not use the parking position for
an extended length of time, other­wise the battery may discharge.

@

1. Fuel level warning light “”

2. High beam indicator light “”

3. Turn signal indicator light “”

4. Neutral indicator light “”

5. Engine trouble warning light “”

EAU03034

Indicator and warning lights

EAU00079

Fuel level warning light “”

This warning light comes on when the
fuel level drops below approximately

3.5 L. When this occurs, turn the fuel
cock lever to the “RES” position and re­fuel as soon as possible.

EAU00063

High beam indicator light “”

This indicator light comes on when the
high beam of the headlight is switched
on.

EAU00057

Turn signal indicator light “”

This indicator light flashes when the
turn signal switch is pushed to the left
or right.

EAU00061

Neutral indicator light “”

This indicator light comes on when the
transmission is in the neutral position.

EAU00091

Engine trouble warning light “”

This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc­curs, have the Yamaha dealer check
the self-diagnosis system.

3

3-2

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

Pushing the mode button (left) switch­es the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP A” and “TRIP B” in the following
order:

CB-27E

ODO TRIP A TRIP B

3

1. Odometer/tripmeter/clock

2. Speedometer

3. Fuel gauge

4. Set button

5. Mode button

EAU03393

Speedometer unit

The speedometer unit is equipped with
a speedometer, an odometer and two
tripmeters. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeters
show the distance traveled since they
were last set to zero.

To reset a tripmeter, select it by push­ing the mode button (left), and then
hold down the set button (right) for at
least one second. The tripmeters can
be used to estimate the distance that
can be traveled with a full tank of fuel.
This information will enable you to plan
future fuel stops.

@

This motorcycle is not equipped with a
tachometer; however, it has a built-in
engine speed limiter, which prevents
the engine speed from exceeding ap­proximately 4,400 r/min.

@

3-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU03400

Self-diagnosis device

This model is equipped with a self-di­agnosis device for various electrical
circuits.
If any of those circuits are defective,
the engine trouble warning light will
come on or the fuel level warning light
will flash. If this occurs, have a Yamaha
dealer check the motorcycle.

CAUTION:

@

To prevent engine damage, be sure
to consult a Yamaha dealer as soon
as possible if this occurs.

@

ECA00061

EAU00113

Fuel gauge

The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
“E”, refuel as soon as possible.

NOTE:

@

Do not allow the fuel tank to empty it­self completely.

@

EAU00109

Anti-theft alarm (optional)

This motorcycle can be equipped with
an optional anti-theft alarm by a
Yamaha dealer. Contact a Yamaha
dealer for more information.

3

3-4

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Clock

2. Set button

3. Mode button

EAU01736

Clock

The digital clock shows the time re­gardless of the main switch position.

To set the clock:

1. Turn the key to “ON”.

2. Press both the set button (right)
and the mode button (left) simulta­neously until the hours and min­utes flash.

3. Push the left button and only the
hour display will flash.

4. Push the right button to change
the hours.

5. Push the left button and only the
minute display will flash.

6. Push the right button to change
the minutes.

7. Push the left button and both the
hours and minutes will flash.

3-5

8. Push the right button for two sec­onds to set the clock.

1. Pass switch “”

2. Dimmer switch “ / ”

3. Turn signal switch “ / ”

4. Horn switch “”

EAU00118

Handlebar switches

EAU00119

Pass switch “”

Press this switch to flash the headlight.

EAU03888

Dimmer switch “ / ”

Set this switch to “” for the high
beam and to “” for the low beam.

INSTRUMENT AND CONTROL FUNCTIONS

EAU03889

Turn signal switch “ / ”

To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When
released, the switch returns to the cen­ter position. To cancel the turn signal
lights, push the switch in after it has re­turned to the center position.

1. Engine stop switch “ / ”

EAU00129

Horn switch “”

Press this switch to sound the horn.

2. Light switch “ //”

3. Start switch “”

Engine stop switch “ / ”

Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergen­cy, such as when the motorcycle over­turns or when the throttle cable is
stuck.

Light switch “ //”

Set this switch to “” to turn on the
auxiliary light, meter lighting and tail­light. Set the switch to “” to turn on
the headlight also. Set the switch to
“” to turn off all the lights.

3

EAU03890

EAU03898

3-6

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

3

1. Engine stop switch “ / ”

2. Light switch “ //”

3. Start switch “”

EAU00143

Start switch “”

Push this switch to crank the engine
with the starter.

EC000005

CAUTION:

@

See page 5-1 for starting instruc­tions prior to starting the engine.

@

1. Clutch lever 1. Shift pedal

EAU00152

Clutch lever

The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle­bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth

Shift pedal

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 5-speed con­stant-mesh transmission equipped on

this motorcycle.
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition
circuit cut-off system. (See page 3-16

@

Use your toes or heel to shift up and

your toes to shift down.

@

for an explanation of the ignition circuit
cut-off system.)

3-7

EAU01215

INSTRUMENT AND CONTROL FUNCTIONS

1. Brake lever 1. Brake pedal

EAU00158

Brake lever

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle­bar grip.

Brake pedal

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

3

EAU00162

3-8

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

To install the fuel tank cap

1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock and with the “” mark
facing forward.

2. Turn the key counterclockwise to
the original position, remove it,

3

and then close the lock cover.

1. Fuel tank cap lock cover

2. “” mark
a. Unlock.
b. Lock.

Fuel tank cap

To remove the fuel tank cap

Slide the lock cover open, insert the
key into the lock, and then turn it
1/4 turn clockwise. The lock will be re­leased and the fuel tank cap can be
removed.

EAU02917

NOTE:

@

The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.

@

@

WARNING

EW000024

Make sure that the fuel tank cap is
properly installed before riding.

@

3-9

1. Fuel tank filler tube

2. Fuel level

EAU03753

Fuel

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

_

Do not overfill the fuel tank, oth-

●

erwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot

●

engine.

_

EW000130

INSTRUMENT AND CONTROL FUNCTIONS

EAU00185

CAUTION:

@

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

@

EAU04202

Recommended fuel:

REGULAR UNLEADED
GASOLINE ONLY

Fuel tank capacity:

Total amount:

20 L

Reserve amount:

3.5 L

ECA00102

CAUTION:

_

Use only unleaded gasoline. The
use of leaded gasoline will cause se­vere damage to internal engine
parts such as the valves and piston
rings, as well as to the exhaust sys­tem.

_

Your Yamaha engine has been de­signed to use regular unleaded gaso­line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.

1. Fuel tank breather hose

Fuel tank breather hose

Before operating the motorcycle:

Check the fuel tank breather hose

●

connection.
Check the fuel tank breather hose

●

for cracks or damage, and replace
it if damaged.
Make sure that the end of the fuel

●

tank breather hose is not blocked,
and clean it if necessary.

3

EAU02955

3-10

INSTRUMENT AND CONTROL FUNCTIONS

RES: reserve position

OFF: closed position

3

1. Pointed end positioned over “OFF”

Fuel cock

The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:

OFF

With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not run­ning.

EAU03050

ON: normal position

1. Pointed end positioned over “ON”

ON

With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.

1. Pointed end positioned over “RES”

RES

This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first oppor­tunity. Be sure to set the lever back to
“ON” after refueling!

3-11

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

3

EAU04038

Starter (choke) knob “”

Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction a to turn on
the starter (choke).
Move the knob in direction b to turn off
the starter (choke).

EAU03372

Locking the steering with a
padlock

In addition to the main switch/steering
lock, there are brackets on the right
side of the steering head pipe for lock­ing the steering with a padlock. To do
so, turn the handlebar until the holes in
the two brackets are aligned, and then
lock the steering with a suitable
padlock.

3-12

EAU03785*

Rider seat

To remove the rider seat

1. Insert the key into the main switch,
and then turn it counterclockwise
to “OPEN”.

_

Do not push inward when turning the
key.

_

2. Pull the rider seat off.

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

EW000030

_

Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.

_

3

1. Projection

2. Seat holder

To install the rider seat

1. Insert the projection on the rear of
the rider seat into the seat holder
as shown, and then push the front
of the seat down to lock it in place.

2. Remove the key from the main
switch if the motorcycle will be left
unattended.

NOTE:

_

Make sure that the rider seat is proper­ly secured before riding.

_

1. Helmet holder

EAU00264

Helmet holder

The helmet holder is located under the
rider seat.

To secure a helmet to the helmet
holder

1. Remove the rider seat. (See
page 3-12 for rider seat removal
and installation procedures.)

2. Attach the helmet to the helmet
holder, and then securely install
the seat.

3-13

To release the helmet from the hel­met holder

Remove the rider seat, remove the hel­met from the helmet holder, and then
install the seat.

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

3

1. Locknut

2. Spring preload adjusting nut

EAU03591*

Adjusting the shock absorber
assembly

This shock absorber assembly is
equipped with a spring preload adjust­ing nut.

CAUTION:

_

Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.

_

Adjust the spring preload as follows.

1. Loosen the locknut.

EC000015

1. Special wrench A. Distance A

2. To increase the spring preload
and thereby harden the suspen­sion, turn the adjusting nut in di­rection a. To decrease the spring
preload and thereby soften the
suspension, turn the adjusting nut
in direction b.

3-14

_

The spring preload setting is deter­mined by measuring distance A, shown
in the illustration. The shorter distance
A is, the lower the spring preload; the
longer distance A is, the higher the
spring preload.

_

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

Spring preload:

Minimum (soft)/standard:

Distance A = 42.5 mm

Maximum (hard):

Distance A = 51.5 mm

3. Tighten the locknut to the speci-

3

fied torque.

Tightening torque:

Locknut:

35 Nm (3.5 m·kgf)

CAUTION:

_

Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.

_

EC000018

EAU00315

WARNING

@

This shock absorber contains high­ly pressurized nitrogen gas. For
proper handling, read and under­stand the following information be­fore handling the shock absorber.
The manufacturer cannot be held re­sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to

●

open the gas cylinder.
Do not subject the shock ab-

●

sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
Do not deform or damage the

●

gas cylinder in any way, as this
will result in poor damping per­formance.
Always have a Yamaha dealer

●

service the shock absorber.

@

EAU00330

Sidestand

The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.

@

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)

@

3-15

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

EW000044

WARNING

@

The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth­erwise the sidestand could contact
the ground and distract the opera­tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side­stand before starting off. Therefore,
check this system regularly as de­scribed below and have a Yamaha
dealer repair it if it does not function
properly.

@

EAU03720

Ignition circuit cut-off system

The ignition circuit cut-off system (com­prising the sidestand switch, clutch
switch and neutral switch) has the fol­lowing functions.

It prevents starting when the trans-

●

mission is in gear and the side­stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-

●

mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
It cuts the running engine when

●

the transmission is in gear and the
sidestand is moved down.

Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.

EW000045

_

If a malfunction is noted, have a
Yamaha dealer check the system
before riding.

_

3

3-16

INSTRUMENT AND CONTROL FUNCTIONS

CD-01E

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “”.

3. Turn the key to “ON”.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

3

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?

YES

YES NO

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?

YES NO

The system is OK.

The motorcycle can be ridden.

NO

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

until

until

until

3-17

PRE-OPERATION CHECKS

Pre-operation check list ..................................................................... 4-1

4

4-

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec­tion, to check the following points before each ride.

Pre-operation check list

CO-01E

ITEM CHECKS PAGE

• Check fuel level in fuel tank.

4

Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check lever free play.

• Adjust if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

• Make sure that operation is smooth.

• Check free play.

• If necessary, have Yamaha dealer make adjustment or lubricate.

3-9–3-10

6-8–6-11

6-22, 6-23–6-26

6-22–6-26

6-21, 6-30

6-17

EAU01114

EAU03439

4-1

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Control cables

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals
and switches

Sidestand switch

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.

@

WARNING

@

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.

@

• Make sure that operation is smooth.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

—

6-17–6-20

6-29

6-30

6-30

—

—

3-16

EWA00033

4

4-2

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine ............................................................................ 5-1

Starting a warm engine ..................................................................... 5-3

Shifting .............................................................................................. 5-3

Recommended shift points (for Switzerland only) ............................. 5-4

Tips for reducing fuel consumption ................................................... 5-4

Engine break-in ................................................................................. 5-5

Parking .............................................................................................. 5-6

5

5-

WARNING

OPERATION AND IMPORTANT RIDING POINTS

EAU00372

●

Never start the engine or oper­ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con­sciousness and death within a
short time. Always make sure
that there is adequate ventila­tion.

●

EAU00373

WARNING

@

5

●

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re­garding any control or function

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com­pletely, it could contact the
ground and distract the opera­tor, resulting in a possible loss
of control.

@

that you do not thoroughly un­derstand.

Starting the engine

In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral

●

position.
The transmission is in gear with

●

the clutch lever pulled and the
sidestand up.

@

●

Before starting the engine,
check the function of the igni­tion circuit cut-off system ac­cording to the procedure
described on page 3-16.

●

Never ride with the sidestand
down.

@

EAU03515*

EW000054

5-1

1. Turn the fuel cock lever to “ON”.

CAUTION:

NOTE:

2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.

3. Shift the transmission into the neu­tral position.

OPERATION AND IMPORTANT RIDING POINTS

6. After starting the engine, move the

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-12 for starter (choke)
operation.)

5. Start the engine by pushing the
start switch.

starter (choke) knob back halfway.

@

For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!

@

7. When the engine is warm, turn the
starter (choke) off.

@

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

@

ECA00055

5

NOTE:

@

When the transmission is in the neutral
position, the neutral indicator light

should be on, otherwise have a
Yamaha dealer check the electrical
circuit.

@

NOTE:

@

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre­serve the battery. Do not crank the en­gine more than 10 seconds on any one
attempt.

@

5-2

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

Starting a warm engine

Follow the same procedure as for start­ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.

5

EAU01258

1. Shift pedal
N. Neutral position

EAU00423

Shifting

Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il­lustration.

NOTE:

@

To shift the transmission into the neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

@

@

Even with the transmission in

●

the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.
Always use the clutch while

●

changing gears to avoid dam­aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.

@

EC000048

5-3

OPERATION AND IMPORTANT RIDING POINTS

EAU02941

Recommended shift points

(for Switzerland only)

The recommended shift points during

acceleration are shown in the table be-

low.

CF-01E

1st → 2nd
2nd → 3rd
3rd → 4th
4th → 5th

NOTE:

@

When shifting down two gears at a

time, reduce the speed accordingly

(e.g., down to 35 km/h when shifting

from 4th to 2nd gear).

@

Shift point

(km/h)

23
36
50
60

EAU00424

Tips for reducing fuel
consumption

Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Thoroughly warm up the engine.

●

Turn the starter (choke) off as

●

soon as possible.
Shift up swiftly, and avoid high en-

●

gine speeds during acceleration.
Do not rev the engine while shift-

●

ing down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-

●

ting it idle for an extended length
of time (e.g., in traffic jams, at traf­fic lights or at railroad crossings).

5

5-4

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

Engine break-in

There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea­son, you should read the following ma­terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the en­gine wear and polish themselves to the
correct operating clearances. During

5

this period, prolonged full-throttle oper­ation or any condition that might result
in engine overheating must be avoided.

EAU01128

EAU01740*

0–1,000 km

Avoid prolonged operation above
1/3 throttle.

1,000–1,600 km

Avoid prolonged operation above
1/2 throttle.

ECA00026*

CAUTION:

@

After 1,000 km of operation, the en­gine oil and transfer case oil must
be changed, and the oil filter car­tridge replaced.

@

1,600 km and beyond

The vehicle can now be operated nor­mally.

EC000049

@

If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

@

5-5

EAU00457

Parking

When parking, stop the engine, re-

move the key from the main switch,

and then turn the fuel cock lever to

“OFF”.

WARNING

@

Since the engine and exhaust

●

system can become very hot,
park in a place where pedestri­ans or children are not likely to
touch them.
Do not park on a slope or on

●

soft ground, otherwise the
motorcycle may overturn.

@

EW000058

OPERATION AND IMPORTANT RIDING POINTS

5

5-6

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-3

Removing and installing the panel .......................6-6

Checking the spark plugs .................................... 6-7

Engine oil and oil filter cartridge ..........................6-8

Transfer case oil ................................................. 6-12

Cleaning the air filter element ............................6-13

Adjusting the carburetor ..................................... 6-16

Adjusting the engine idling speed ...................... 6-16

Adjusting the throttle cable free play ..................6-17

Adjusting the valve clearance ............................ 6-17

Tires ................................................................... 6-17

Spoke wheels .................................................... 6-20

Adjusting the clutch lever free play .................... 6-21

Adjusting the brake lever free play ..................... 6-22

Adjusting the brake pedal position .....................6-22

Adjusting the rear brake light switch ..................6-23

Checking the front and rear brake pads .............6-23

Checking the brake fluid level ............................ 6-25

Changing the brake fluid .................................... 6-26

Drive belt slack .................................................. 6-26

Checking and lubricating the cables ................. 6-28

Checking and lubricating the throttle

grip and cable ................................................. 6-29

Checking and lubricating the brake and

shift pedals ...................................................... 6-29

Checking and lubricating the brake and

clutch levers .................................................... 6-30

Checking and lubricating the sidestand ............ 6-30

Checking the front fork ...................................... 6-31

Checking the steering ....................................... 6-31

Checking the wheel bearings ............................ 6-32

Battery ............................................................... 6-33

Replacing the fuses .......................................... 6-35

Replacing the headlight bulb ............................. 6-36

Replacing a turn signal light bulb or the

tail/brake light bulb .......................................... 6-38

Troubleshooting ................................................. 6-38

Troubleshooting chart ........................................ 6-39

6

6-

PERIODIC MAINTENANCE AND MINOR REPAIR

VALS MAY NEED TO BE SHORT­ENED.

WARNING

@

If you are not familiar with motor­cycle maintenance work, have a
Yamaha dealer do it for you.

@

EAU00464

Safety is an obligation of the owner.
Periodic inspection, adjustment and lu­brication will keep your vehicle in the
safest and most efficient condition pos-

6

sible. The most important points of in­spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen­eral guide under normal riding condi­tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI­CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-

EAU00462

EW000060

1. Owner’s tool kit

EAU03711

Owner’s tool kit

The owner’s tool kit is located under
the rider seat. (See page 3-12 for rider
seat removal and installation proce­dures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

6-1

NOTE:

_

If you do not have the tools or experi­ence required for a particular job, have
a Yamaha dealer perform it for you.

_

_

WARNING

EW000063

Modifications not approved by

Yamaha may cause loss of perfor-

mance and render the vehicle un­safe for use. Consult a Yamaha
dealer before attempting any chang­es.

_

PERIODIC MAINTENANCE AND MINOR REPAIR

6

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart

NOTE:

_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

●

From 50,000 km, repeat the maintenance intervals starting from 10,000 km.

●

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-

●

cal skills.

_

CP-01E

NO. ITEM CHECK OR MAINTENANCE JOB

1

Fuel line • Check fuel hoses for cracks or damage. √√√√ √

*

Fuel filter • Check condition. √√

2

*

• Check condition.

3 Spark plugs

6

4

Valves

*

5 Air filter element

6Clutch

7

Front brake

*

8

Rear brake

*

• Clean and regap.

•Replace. √√

• Check valve clearance.

• Adjust.

• Clean. √√

•Replace. √√

• Check operation.

• Adjust.

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)

• Replace brake pads. Whenever worn to the limit

• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)

• Replace brake pads. Whenever worn to the limit

EAU03685

ODOMETER READING (× 1,000 km)

1 10203040

√√

√√√√

√√√√√

√√ √ √√ √

√√ √ √√ √

ANNUAL

CHECK

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

9*Brake hoses

10

Wheels

*

11

Tires

*

12

Wheel bearings • Check bearing for looseness or damage. √√√√

*

13

Swingarm

*

14

Drive belt

*

15

Steering bearings

*

16

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √√√√ √

*

17 Sidestand

Sidestand switch • Check operation. √√√√√ √

18

*

Front fork • Check operation and for oil leakage. √√√√

19

*

Shock absorber

20

*

assembly

Rear suspension relay
arm and connecting arm

21

*

pivoting points

22

Carburetor

*

• Check for cracks or damage. √√√√ √

• Replace. (See NOTE on page 6-5.) Every 4 years

• Check runout, spoke tightness and for damage.

• Tighten spokes if necessary.

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check operation and for excessive play. √√√√

• Lubricate with lithium-soap-based grease. Every 50,000 km

• Check belt tension.

• Make sure that the rear wheel is properly aligned.

• Check bearing play and steering for roughness. √√√√√

• Lubricate with lithium-soap-based grease. Every 50,000 km

• Check operation.

• Lubricate.

• Check operation and shock absorber for oil leakage. √√√√

• Check operation. √√√√

• Lubricate with lithium-soap-based grease. √√

• Check starter (choke) operation.

• Adjust engine idling speed.

6-4

ODOMETER READING (× 1,000 km)

1 10203040

√√√√

√√√√ √

Every 4,000 km

√√√√ √

√√√√√ √

ANNUAL

CHECK

6

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

23 Engine oil

24 Engine oil filter cartridge • Replace. √√√

25

Transfer case oil

*

Front and rear brake

26

*

switches

27 Moving parts and cables • Lubricate. √√√√ √

Lights, signals and

28

*

switches

NOTE:

_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

●

6

Hydraulic brake service

●

• Change.

• Check oil level and vehicle for oil leakage.

• Check oil level. √√

• Change. √√√

• Check operation. √√√√√ √

• Check operation.

• Adjust headlight beam.

ODOMETER READING (× 1,000 km)

1 10203040

√√√√√ √

√√√√√ √

• Regularly check and, if necessary, correct the brake fluid level.

• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake

fluid.

• Replace the brake hoses every four years and if cracked or damaged.

_

ANNUAL

CHECK

EAU03884

6-5

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel A 1. Bolt

EAU01777

Removing and installing the
panel

The panel shown above needs to be
removed to perform some of the main­tenance jobs described in this chapter.
Refer to this section each time the pan­el needs to be removed and installed.

Panel A

To remove the panel
Remove the bolt, and then pull the pan­el off as shown.

EAU00491

To install the panel
Place the panel in the original position,
and then install the bolt.

6

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

Checking the spark plugs

The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte­nance and lubrication chart. In addition,
the condition of the spark plugs can re­veal the condition of the engine.
The porcelain insulator around the cen­ter electrode of each spark plug should

6

be a medium-to-light tan (the ideal col­or when the motorcycle is ridden nor­mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif­ferent color, the engine could be defec­tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.

EAU01639

a. Spark plug gap

Specified spark plug:

DPR7EA-9/NGK or
X22EPR-U9/DENSO

Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.

Spark plug gap:

0.8–0.9 mm

Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf)

@

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci­fied torque as soon as possible.

@

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

NOTE:

ECA00021

CAUTION:

@

Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in.

@

1. Engine oil filler cap

EAU04212

Engine oil and oil filter
cartridge

The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car­tridge replaced at the intervals speci­fied in the periodic maintenance and
lubrication chart.

To check the engine oil level

1. Place the motorcycle on a level
surface and hold it in an upright
position.

_

Make sure that the motorcycle is posi­tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.

_

2. Remove the rider seat. (See
page 3-12 for rider seat removal
and installation procedures.)

3. Start the engine, warm it up until
the engine oil has reached a nor­mal temperature of 60 °C, let it
continue to idle for ten seconds,
and then turn the engine off.

_

To achieve the proper engine oil tem­perature for an accurate oil level read­ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature.

_

6

6-8

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

_

When adding oil, be careful not to over­fill the engine; the oil level rises faster
starting from the half level portion on
the dipstick.

_

6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.

1. Maximum level mark

2. Minimum level mark

3. Dipstick

4. Wait a few minutes until the oil set­tles, remove the oil filler cap, wipe

6

the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.

NOTE:

_

The engine oil should be between the
minimum and maximum level marks.

_

5. If the engine oil is below the mini­mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.

7. Install the rider seat.

CAUTION:

_

Make sure that the oil filler cap is se­curely tightened, otherwise oil may
seep out when the engine is run­ning.

_

ECA00027

1. Engine oil drain bolt (oil tank)

To change the engine oil
(with or without oil filter cartridge
replacement)

1. Start the engine, warm it up for
several minutes, and then turn it
off.

2. Place an oil pan under the oil tank
to collect the used oil.

3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the oil tank.

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil drain bolt (crankcase) 1. Engine oil filter cartridge

NOTE:

_

Skip steps 4–8 if the oil filter cartridge is
not being replaced.

_

4. Place an oil pan under the engine
to collect the used oil.

5. Remove the engine oil drain bolt to
drain the oil from the crankcase.

6. Remove the oil filter cartridge with
an oil filter wrench.

NOTE:

_

An oil filter wrench is available at a

Yamaha dealer.

_

7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car­tridge.

NOTE:

_

Make sure that the O-ring is properly
seated.

_

8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf)

9. Install the engine oil drain bolts,
and then tighten them to the spec­ified torque.

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf)

10. Pour only 2.5 L of the specified
amount of recommended engine
oil through the filler hole, insert the
dipstick, and then tighten the oil
filler cap.

11. Start the engine, rev it several
times, and then turn it off.

12. Remove the engine oil filler cap,
and then gradually fill the oil tank
with the remaining oil quantity
while regularly checking the oil
level on the dipstick.

6

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

6

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge
replacement:

3.7 L
With oil filter cartridge
replacement:

4.1 L
Total amount (dry engine):

5.0 L

CAUTION:

_

In order to prevent clutch slip-

●

page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a “CD”
grade or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign mate-

●

rial enters the crankcase.

_

13. Install the engine oil filler cap.

14. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.

15. Turn the engine off, and then
check the oil level and correct it if
necessary.

EC000072*

6-11

1. Transfer case oil filler cap

2. Transfer case oil check bolt

EAU03395

Transfer case oil

The transfer case oil level should be
checked before each ride. In addition,
the oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.

To check the transfer case oil level

1. Place the motorcycle on a level
surface and hold it in an upright
position.

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

@

Make sure that the motorcycle is posi­tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.

@

2. Remove the oil check bolt, and
then check the oil level in the
transfer case.

NOTE:

@

The oil should be at the brim of the
check hole.

@

3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the rec­ommended type to raise it to the
correct level, and then install the
oil filler cap.

4. Install the oil check bolt, and then
tighten it to the specified torque.

Tightening torque:

Transfer case oil check bolt:

7.5 Nm (0.75 m·kgf)

1. Transfer case oil drain bolt

To change the transfer case oil

1. Place an oil pan under the transfer
case to collect the used oil.

2. Remove the drain bolt and the
check bolt to drain the oil from the
transfer case.

3. Install the drain bolt and the check
bolt, and then tighten the drain bolt
to the specified torque.

Tightening torque:

Transfer case oil drain bolt:

17.5 Nm (1.75 m·kgf)

6

6-12

PERIODIC MAINTENANCE AND MINOR REPAIR

5. Start the engine and let it idle for
several minutes while checking
the transfer case for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the
cause.

1. Transfer case oil check hole

4. Remove the oil filler cap, add the
specified amount of the recom­mended transfer case oil, and then
install and tighten the oil filler cap.

6

Recommended transfer case oil:

See page 8-2.

Oil quantity:

0.4 L

CAUTION:

@

Make sure that no foreign material
enters the transfer case.

@

1. Bolt (× 4)

2. Air filter case

EAU03707

Cleaning the air filter element

The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre­quently if you are riding in unusually
wet or dusty areas.

1. Remove the air filter case bolts.

ECA00024

6-13

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Air filter joint clamp screw 1. Screw (× 2)

2. Loosen the air filter joint clamp
screw, and then slightly pull the air
filter case out.

2. Hose (× 2)

3. Air filter case cover

3. Remove the air filter case cover by
removing the screws.

4. Disconnect the hoses shown.

1. Screw (× 2)

2. Hose

5. Remove the air filter element by
removing the screws, and then
disconnect the hose shown.

6

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

6. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.

6

If the air filter element is damaged,
replace it.

1. Screw (× 2)

2. Hose

7. Install the air filter element by in­serting it into the air filter case,
then installing the screws, and
then connect the hose shown.

8. Install the air filter case cover by
installing the screws.

6-15

1. Hose (× 2)

9. Connect the hoses shown.

10. Install the air filter case by pushing
it onto the air filter joint, and then
tighten the air filter joint clamp
screw.

11. Install the air filter case by install­ing the bolts.

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

EAU00629

Adjusting the carburetor

The carburetor is an important part of
the engine and requires very sophisti­cated adjustment. Therefore, most car­buretor adjustments should be left to a

Yamaha dealer, who has the neces-

sary professional knowledge and expe­rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.

CAUTION:

@

The carburetor has been set and ex­tensively tested at the Yamaha fac­tory. Changing these settings
without sufficient technical knowl­edge may result in poor perfor­mance of or damage to the engine.

@

EC000094

EAU01168

Adjusting the engine idling
speed

The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.

NOTE:

@

A diagnostic tachometer is needed to
make this adjustment.

@

1. Attach the tachometer to the spark
plug lead.

2. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev­ving it to 4,000–4,400 r/min.

NOTE:

@

The engine is warm when it quickly re­sponds to the throttle.

@

1. Throttle stop screw

3. Check the engine idling speed
and, if necessary, adjust it to spec­ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di­rection a. To decrease the engine
idling speed, turn the screw in di­rection b.

Engine idling speed:

850–950 r/min

@

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.

@

6

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the valve clearance

The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.

a. Throttle cable free play

EAU00635

Adjusting the throttle cable
free play

The throttle cable free play should

6

measure 4–6 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.

EAU00637

EAU01848

Tires

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified tires.

Tire air pressure

The tire air pressure should be
checked and, if necessary, adjusted
before each ride.

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

@

The tire air pressure must be

●

checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
The tire air pressure must be

●

adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car­go, and accessories approved
for this model.

@

CE-01E

Load* Front Rear

Up to 90 kg

90 kg–maximum

CE-07E

Maximum load* 196 kg

* Total weight of rider, passenger, cargo and

accessories

Tire air pressure

(measured on cold tires)

250 kPa

2.50 kgf/cm

2.50 bar

250 kPa

2.50 kgf/cm

2.50 bar

2

2

250 kPa

2.50 kgf/cm

2.50 bar

280 kPa

2.80 kgf/cm

2.80 bar

EW000082

WARNING

@

Because loading has an enormous
impact on the handling, braking,
performance and safety characteris­tics of your motorcycle, you should
keep the following precautions in
mind.

NEVER OVERLOAD THE

●

MOTORCYCLE! Operation of an
overloaded motorcycle may re­sult in tire damage, loss of con­trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso­ries does not exceed the speci­fied maximum load for the

2

2

vehicle.

EWA00012

Do not carry along loosely

●

packed items, which can shift
during a ride.
Securely pack the heaviest

●

items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
Adjust the suspension and tire

●

air pressure with regard to the
load.
Check the tire condition and air

●

pressure before each ride.

@

6

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

1. Tire sidewall
a. Tire tread depth

Tire inspection

The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail

6

or glass fragments in it, or if the side­wall is cracked, have a Yamaha dealer
replace the tire immediately.

CE-08E

Minimum tire tread depth
(front and rear)

NOTE:

@

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.

@

1.6 mm

WARNING

@

Have a Yamaha dealer replace

●

excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta­bility and can lead to loss of
control.
The replacement of all wheel-

●

and brake-related parts, includ­ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl­edge and experience.

@

EW000079

Tire information

This motorcycle is equipped with tube
tires.

EW000078

@

The front and rear tires should

●

be of the same make and de­sign, otherwise the handling
characteristics of the motor­cycle cannot be guaranteed.
After extensive tests, only the

●

tires listed below have been ap­proved for this model by
Yamaha Motor Co., Ltd.

@

CE-10E

FRONT

Manufacturer Size Model

Dunlop

Bridgestone

REAR

Manufacturer Size Model

Dunlop

Bridgestone

130/90-16 67H

130/90-16 M/C 67H

130/90-16 67H

130/90-16 M/C 67H

150/80B-16 71H

150/80B-16 M/C 71H

150/80B-16 71H

150/80B-16 M/C 71H

D404FL

G703F

D404

G702

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

@

Have a Yamaha dealer replace

●

excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta­bility and can lead to loss of
control.
The replacement of all wheel-

●

and brake-related parts, includ­ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl­edge and experience.
It is not recommended to patch

●

a punctured tube. If unavoid­able, however, patch the tube
very carefully and replace it as
soon as possible with a high­quality product.

@

EAU00681

EAU00685

Spoke wheels

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked

●

for cracks, bends or warpage, and
the spokes for looseness or dam­age before each ride. If any dam­age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced

●

whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han­dling characteristics, and a short­ened tire life.
Ride at moderate speeds after

●

changing a tire since the tire sur­face must first be “broken in” for it
to develop its optimal characteris­tics.

6-20

6

PERIODIC MAINTENANCE AND MINOR REPAIR

7. Tighten the locknut at the clutch
lever and the crankcase.

1. Locknut

2. Clutch lever free play adjusting bolt
c. Clutch lever free play

Adjusting the clutch lever free
play

6

The clutch lever free play should mea­sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the clutch le­ver.

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.

EAU00694

1. Clutch lever free play adjusting nut

2. Locknut

3. If the specified clutch lever free
play could be obtained as de­scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the
clutch lever in direction a to loos­en the clutch cable.

5. Loosen the locknut at the crank­case.

6. To increase the clutch lever free
play, turn the adjusting nut in di­rection a. To decrease the clutch
lever free play, turn the adjusting
nut in direction b.

6-21

1. Locknut

2. Brake lever free play adjusting bolt
c. Brake lever free play

EAU00696

Adjusting the brake lever free
play

The brake lever free play should mea­sure 2–5 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the brake le­ver.

2. To increase the brake lever free
play, turn the adjusting bolt in di­rection a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.

3. Tighten the locknut.

PERIODIC MAINTENANCE AND MINOR REPAIR

EW000099

WARNING

@

After adjusting the brake lever

●

free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the

●

brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy­draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin­ish the braking performance,
which may result in loss of con­trol and an accident.

@

a. Distance between brake pedal and footrest

EAU01746

Adjusting the brake pedal
position

The top of the brake pedal should be
positioned approximately 100 mm
above the top of the footrest as shown.
Periodically check the brake pedal po­sition and, if necessary, have a
Yamaha dealer adjust it.

6

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

@

A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be­fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.

@

6

EW000109

EAU00721

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart.

1. Rear brake light switch

2. Rear brake light switch adjusting nut

EAU00713

Adjusting the rear brake light
switch

The rear brake light switch, which is ac­tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

Front

1. Brake pad wear indicator groove (× 2)

EAU03938

Front brake pads

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with­out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap­peared, have a Yamaha dealer replace
the brake pads as a set.

Rear

1. Brake pad wear indicator groove

EAU03939

Rear brake pads

Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with­out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap­peared, have a Yamaha dealer replace
the brake pads as a set.

6

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

Front

1. Minimum level mark

Checking the brake fluid level

Insufficient brake fluid may allow air to
enter the brake system, possibly caus­ing it to become ineffective.

6

Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu­id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys­tem for leakage.
Observe these precautions:

When checking the fluid level,

●

make sure that the top of the brake
fluid reservoir is level.

EAU03294

Rear

1. Minimum level mark

Use only the recommended quali-

●

ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor­mance.

Recommended brake fluid: DOT 4

Refill with the same type of brake

●

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Be careful that water does not en-

●

ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

6-25

Brake fluid may deteriorate paint-

●

ed surfaces or plastic parts. Al­ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-

●

mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud­denly, have a Yamaha dealer
check the cause.

EAU03976

NOTE:

Changing the brake fluid

Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte­nance and lubrication chart. In addition,
have the oil seals of the master cylin­ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two

●

years.
Brake hoses: Replace every four

●

years.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Drive belt

2. Marks
a. Drive belt slack

EAU01830

Drive belt slack

The drive belt slack should be checked
before each ride and adjusted if neces­sary.

To check the drive belt slack

1. Place the motorcycle on a level
surface and hold it in an upright
position.

2. Note the current position of the
drive belt using the marks near the
check hole.

1. Belt tension gauge

@

The marks near the drive belt check
hole are 5 mm apart.

@

3. Note the position of the drive belt
with a force of 45 N (4.5 kgf) ap­plied to the belt with a belt tension
gauge as shown.

4. Calculate the drive belt slack by
subtracting the measurement not­ed in step 2 from the measure­ment noted in step 3.

6

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

Drive belt slack:

7.5–13 mm

5. If the drive belt slack is incorrect,
adjust it as follows.

1. Wheel axle nut 1. Brake caliper bracket bolt

To adjust the drive belt slack

1. Loosen the rear wheel axle nut
and the brake caliper bracket bolt.

6

EAU01748

2. Loosen the drive belt puller lock­nut on each side of the swingarm.

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

1. Drive belt slack adjusting bolt (× 2)

2. Drive belt puller locknut (× 2)

3. Wheel axle

3. To tighten the drive belt, turn the
adjusting bolt on each side of the
swingarm in direction a. To loos­en the drive belt, turn the adjusting
bolt on each side of the swingarm
in direction b, and then push the
rear wheel forward.

NOTE:

@

Turn each adjusting bolt the same
amount for proper wheel alignment.

@

4. Tighten the locknuts.

ECA00025

CAUTION:

@

Improper drive belt slack will over­load the engine. Keep the drive belt
slack within the specified range.

@

5. Tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.

Tightening torques:

Axle nut:

150 Nm (15 m·kgf)

Brake caliper bracket bolt:

48 Nm (4.8 m·kgf)

EAU02962

Checking and lubricating the
cables

The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca­bles and cable ends should be lubricat­ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:

Engine oil

EW000112

_

Damage to the outer sheath may in­terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

_

6

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU04034

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip should
be checked before each ride. In addi­tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.

Checking and lubricating the
brake and shift pedals

The operation of the brake and shift

6

pedals should be checked before each
ride, and the pedal pivots should be lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EAU03370

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

Checking and lubricating the
brake and clutch levers

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EAU03164

6-30

EAU03165

Checking and lubricating the
sidestand

The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.

@

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

@

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EW000113

6

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

Checking the front fork

The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main­tenance and lubrication chart.

To check the condition

WARNING

@

Securely support the motorcycle so
that there is no danger of it falling
over.

@

Check the inner tubes for scratches,

6

damage and excessive oil leakage.

EAU02939

EW000115

To check the operation

1. Place the motorcycle on a level
surface and hold it in an upright
position.

2. While applying the front brake,
push down hard on the handle­bars several times to check if the
front fork compresses and re­bounds smoothly.

EC000098

CAUTION:

@

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

@

EAU00794

Checking the steering

Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol­lows at the intervals specified in the pe­riodic maintenance and lubrication
chart.

1. Place a stand under the engine to
raise the front wheel off the
ground.

EW000115

@

Securely support the motorcycle so
that there is no danger of it falling
over.

@

6-31

2. Hold the lower ends of the front
fork legs and try to move them for­ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01144

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica­tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

6

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Battery

Battery

This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is

6

no need to check the electrolyte or to
add distilled water.

CAUTION:

@

Never attempt to remove the battery
cell seals, as this would permanent­ly damage the battery.

@

EAU00800

EC000101

WARNING

@

Electrolyte is poisonous and

●

dangerous since it contains sul­furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al­ways shield your eyes when
working near batteries. In case
of contact, administer the fol­lowing FIRST AID.

• EXTERNAL: Flush with plenty
of water.

• INTERNAL: Drink large quan­tities of water or milk and im­mediately call a physician.

• EYES: Flush with water for
15 minutes and seek prompt
medical attention.

EW000116

Batteries produce explosive hy-

●

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTER-

●

IES OUT OF THE REACH OF
CHILDREN.

@

To charge the battery

Have a Yamaha dealer charge the bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op­tional electrical accessories.

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

To store the battery

1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.

2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

CAUTION:

@

Always keep the battery

●

charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)

●

battery, a special (constant­voltage) battery charger is re­quired. Using a conventional
battery charger will damage the
battery. If you do not have ac­cess to a sealed-type (MF) bat­tery charger, have a Yamaha
dealer charge your battery.

@

EC000102

6

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt 1. Signaling system fuse

EAU04245*

Replacing the fuses

The main fuse box is located behind
panel A. (See page 6-6 for panel re­moval and installation procedures.)

6

The fuse box, which contains the fuses
for the individual circuits, is located be­hind panel A. (See page 6-6 for panel
removal and installation procedures.)

2. Ignition fuse

3. Headlight fuse

4. Carburetor heater fuse

5. Backup fuse (odometer)

6. Spare fuse (× 3)

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off
the electrical circuit in question.

2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

1. Main fuse

2. Spare main fuse

Specified fuses:

Main fuse: 30 A
Ignition fuse: 15 A
Signaling system fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse: 10 A
Backup fuse (odometer): 5 A

6-35

EC000103

CAUTION:

_

Do not use a fuse of a higher amper­age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.

_

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.

4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2) 1. Headlight coupler

EAU04189

Replacing the headlight bulb

This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.

1. Remove the headlight unit by re­moving the screws.

2. Headlight bulb cover

2. Disconnect the headlight coupler,
and then remove the bulb cover.

6

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

1. Headlight bulb holder 1. Do not touch this area.

3. Unhook the headlight bulb holder,
and then remove the defective
bulb.

6

WARNING

_

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

_

4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.

EW000119

EC000105

_

Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af­fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.

_

5. Install the headlight bulb cover,
and then connect the coupler.

6. Install the headlight unit by install­ing the screws.

7. Have a Yamaha dealer adjust the
headlight beam if necessary.

6-37

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2) 1. Screw (× 3)

EAU00855

Replacing a turn signal light
bulb or the tail/brake light
bulb

1. Remove the lens by removing the
screws.

2. Remove the defective bulb by
pushing it in and turning it counter­clockwise.

3. Insert a new bulb into the socket,
push it in, and then turn it clock­wise until it stops.

4. Install the lens by installing the
screws.

CAUTION:

@

Do not overtighten the screws, oth­erwise the lens may break.

@

EC000108

EAU01008

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 chart
represents a quick and easy procedure
for checking these vital systems your­self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace­ment 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

6-38

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01297

Troubleshooting chart

EW000125

WARNING

@

Keep away open flames and do not smoke while checking or working on the fuel system.

@

1. Fuel

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.
Check the compression.

2. Compression

There is compression.

Operate the electric starter.

6

3. Ignition

Remove the spark plugs
and check the electrodes.

4. Battery

Operate the electric starter.

There is no compression.

Wet

Dry

The engine turns over
quickly.

The engine turns over
slowly.

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

6-39

Open the throttle halfway and operate
the electric starter.

The engine does not start.
Check the battery.

The engine does not start.
Have a Yamaha dealer
check the vehicle.

MOTORCYCLE CARE AND STORAGE

Care .................................................................................................. 7-1

Storage .............................................................................................. 7-4

7

7-

CAUTION:

MOTORCYCLE CARE AND STORAGE

EAU03708*

Care

While the open design of a motorcycle
reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop
even if high-quality components are

7

used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.

Before cleaning

1. Cover the muffler outlets with plas­tic bags after the engine has
cooled down.

2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in­stalled.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod­ucts onto seals, gaskets, the drive
belt and wheel axles. Always rinse
the dirt and degreaser off with wa­ter.

Cleaning

_

●

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a
corrosion protection spray.

●

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.

ECA00010

7-1

MOTORCYCLE CARE AND STORAGE

Do not use any harsh chemical

●

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.
Do not use high-pressure wash-

●

ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with

●

a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind­shield. Test the product on a
small hidden part of the wind­shield to make sure that it does
not leave any marks. If the wind­shield is scratched, use a quali­ty plastic polishing compound
after washing.

_

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.

7

7-2

MOTORCYCLE CARE AND STORAGE

WARNING

After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.

NOTE:

_

Salt sprayed on roads in the winter may
remain well into spring.

_

1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.

CAUTION:

7

_

Do not use warm water since it in­creases the corrosive action of the
salt.

_

2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick­el-plated, surfaces to prevent cor­rosion.

ECA00012

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

2. Use a chrome polish to shine
chrome, aluminum and stainless­steel parts, including the exhaust
system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)

3. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal,
including chrome- and nickel-plat­ed, surfaces.

4. Use spray oil as a universal clean­er to remove any remaining dirt.

5. Touch up minor paint damage
caused by stones, etc.

6. Wax all painted and chrome-plat­ed surfaces. Avoid combination
cleaner waxes, many of which
contain abrasives that may mar
the paint or protective finish.

7. Let the motorcycle dry completely
before storing or covering it.

_

Make sure that there is no oil or

●

wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac­etone, and wash the tires with
warm water and a mild deter­gent.
Before operating the motor-

●

cycle test its braking perfor­mance and cornering behavior.

_

EWA00001

7-3

MOTORCYCLE CARE AND STORAGE

ECA00033

CAUTION:

_

Apply spray oil and wax spar-

●

ingly and make sure to wipe off
any excess.
Never apply oil or wax to the

●

drive belt.
Never apply oil or wax to any

●

rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing

●

compounds as they will wear
away the paint.

_

NOTE:

_

Consult a Yamaha dealer for advice on
what products to use.

_

Storage

Short-term

Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.

CAUTION:

_

Storing the motorcycle in a

●

poorly ventilated room or cover­ing it with a tarp, while it is still
wet, will allow water and humid­ity to seep in and cause rust.

ECA00014

To prevent corrosion, avoid

●

damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

_

Long-term

Before storing your motorcycle for sev­eral months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. For motorcycles equipped with a
fuel cock that has an “OFF” posi­tion: Turn the fuel cock lever to
“OFF”.

3. Drain the carburetor float cham­bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

7

7-4

MOTORCYCLE CARE AND STORAGE

NOTE:

7

5. Perform the following steps to pro­tect the cylinders, piston rings, etc.
from corrosion.

a. Remove the spark plug caps and

spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto the

spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are ground­ed. (This will limit sparking during
the next step.)

d. Turn the engine over several times

with the starter. (This will coat the
cylinder walls with oil.)

e. Remove the spark plug caps from

the spark plugs, and then install
the spark plugs and the spark plug
caps.

EWA00003

WARNING

_

To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.

_

6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.

7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna­tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.

8. Cover the muffler outlets with plas­tic bags to prevent moisture from
entering them.

7-5

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex­cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-34.

_

Make any necessary repairs before
storing the motorcycle.

_

SPECIFICATIONS

Specifications .................................................................................... 8-1

Conversion table ............................................................................... 8-5

8

8-

CAUTION:

SPECIFICATIONS

Specifications

CS-01E

Model XV1600A

Dimensions

Overall length 2,500 mm

Overall width 980 mm

Overall height 1,140 mm

Seat height 710 mm

Wheelbase 1,685 mm

Ground clearance 145 mm

Minimum turning radius 3,200 mm

Basic weight (with oil and full
fuel tank)

Engine

Engine type Air-cooled 4-stroke, OHV

Cylinder arrangement V-type 2-cylinder

Displacement 1,602 cm

8

Bore × Stroke 95 × 113 mm

Compression ratio 8.3:1

Starting system Electric starter

Lubrication system Dry sump

332 kg

EAU01038

Engine oil

Ty p e

-20 -10 0

SAE 10W-30

20 30

10

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

40

50 ˚C

Recommended engine oil
classification API Service SE, SF, SG type or

higher

Be sure to use motor oils that do not contain anti-friction

3

modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result­ing in reduced component life and poor engine performance.

Quantity

Without oil filter cartridge
replacement 3.7 L

With oil filter cartridge
replacement 4.1 L

Total amount (dry engine) 5.0 L

8-1

SPECIFICATIONS

Transfer case oil

Type SAE80API “GL-4” Hypoid Gear

Oil

Quantity 0.4 L

Air filter Dry type element

Fuel

Type REGULAR UNLEADED

GASOLINE ONLY

Fuel tank capacity 20 L

Reserve amount 3.5 L

Carburetor

Manufacturer MIKUNI
Model × quantity BSR40 × 1

Spark plug

Manufacturer/model NGK / DPR7EA-9 or

DENSO / X22EPR-U9

Gap 0.8–0.9 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 1.532

Secondary reduction system Belt

Secondary reduction ratio 2.320

Transmission type Constant mesh 5-speed

Operation Left foot

Gear ratio

1st 2.438

2nd 1.579

3rd 1.160

4th 0.906

5th 0.750

Chassis

Frame type Double cradle

Caster angle 32°

Trail 142 mm

Tire

Front

Type Tube tire

Size 130/90-16 67H

130/90-16 M/C 67H

Manufacturer/model Dunlop / D404FL

Bridgestone / G703F

Rear

Type Tube tire

Size 150/80B-16 71H

150/80B-16 M/C 71H

Manufacturer/model Dunlop / D404

Bridgestone / G702

8

8-2

SPECIFICATIONS

Maximum load* 196 kg

Tire air pressure (measured on
cold tires)

Up to 90 kg*

2

Front 250 kPa (2.50 kgf/cm

Rear 250 kPa (2.50 kgf/cm

90 kg–maximum*

Front 250 kPa (2.50 kgf/cm

Rear 280 kPa (2.80 kgf/cm

* Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type Spoke wheel
Size 16 × MT 3.00

16 M/C × MT 3.00

Rear

Type Spoke wheel

8

Brakes

Front

Size 16 × MT 3.50

16 M/C × MT 3.50

Type Dual disc brake

Operation Right hand

Fluid DOT 4

, 2.50 bar)

2

, 2.50 bar)

2

, 2.50 bar)

2

, 2.80 bar)

Rear

Type Single disc brake

Operation Right foot

Fluid DOT 4

Suspension

Front Telescopic fork

Rear Swingarm (link suspension)

Spring/shock absorber

Front Coil spring / oil damper

Rear Coil spring / gas-oil damper

Wheel travel

Front 140 mm

Rear 110 mm

Electrical

Ignition system Transistorized coil ignition

(digital)

Charging system

Type A.C. magneto

Standard output 14 V, 21 A @ 5,000 r/min

Battery

Type YTX20L-BS

Voltage, capacity 12 V, 18 Ah

8-3

Headlight type Quartz bulb (halogen)
Bulb voltage, wattage × quantity

Headlight 12 V, 60/55 W × 1
Tail/brake light 12 V, 5/21 W × 1
Turn signal lights 12 V, 21 W × 4
Auxiliary light 12 V, 4 W × 1
Meter lighting 14 V, 0.6 W × 4
Neutral indicator light 12 V, 1 W × 1
High beam indicator light 12 V, 1 W × 1
Turn indicator light 12 V, 1 W × 1
Fuel level warning light LED × 1
Engine trouble warning light LED × 1

Fuses

Main fuse 30 A

Ignition fuse 15 A

Signaling system fuse 10 A

Headlight fuse 15 A

Carburetor heater fuse 10 A

Backup fuse (odometer) 5 A

SPECIFICATIONS

8

8-4

SPECIFICATIONS

Conversion table

CS-03E

All specification data in this manual are listed in SI and
METRIC UNITS.

Use this table to convert METRIC unit values to IMPERIAL
unit values.

Example:

METRIC VALUE CONVERSION

FACTOR

2 mm × 0.03937 = 0.08 in

8

IMPERIAL VALUE

EAU03941

METRIC SYSTEM TO IMPERIAL SYSTEM

m·kgf

Torque

Weight

Speed km/h

Distance

Volume,
Capacity

Miscellaneous

m·kgf
cm·kgf
cm·kgf

kg
g

km
m
m
cm
mm

cc (cm
cc (cm
L (liter)
L (liter)

kgf/mm
kgf/cm

°

C

Conversion table

Metric unit Conversion factor Imperial unit

×

7.233

×

86.794

×

0.0723

×

0.8679

×

2.205

×

0.03527

×

0.6214 mi/h

×

0.6214

×

3.281

×

1.094

×

0.3937

×

3

)

3

)

2

0.03937

×

0.03527

×

0.06102

×

0.8799

×

0.2199

×

55.997

×

14.2234

×

1.8 + 32

ft·lb
in·lb
ft·lb
in·lb

lb
oz

mi
ft
yd
in
in

oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)

lb/in

2

)

psi (lb/in

°

F

8-5

CONSUMER INFORMATION

Identification numbers ....................................................................... 9-1

Key identification number .................................................................. 9-1

Vehicle identification number ............................................................. 9-1

Model label ........................................................................................ 9-2

9

9-

NOTE:

CONSUMER INFORMATION

EAU02944

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 NUMBER:

CA-02E

2. VEHICLE IDENTIFICATION
NUMBER:

CA-02E

9

3. MODEL LABEL INFORMATION:

CA-01E

1. Key identification number 1. Vehicle identification number

EAU01041

Key identification number

The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new

Vehicle identification number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

key.

@

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor­cycle with the licensing authority in
your area.

@

EAU01039

EAU01043

9-1

1. Model label

EAU01804

Model label

The model label is affixed to the frame
under the rider seat. (See page 3-12 for
rider seat removal and installation pro­cedures.) Record the information on
this label in the space provided. This in­formation will be needed when ordering
spare parts from a Yamaha dealer.

CONSUMER INFORMATION

9

9-2

10-

INDEX

A

Air filter element, cleaning......................6-13

Anti-theft alarm ........................................3-4

B

Battery...................................................6-33

Brake and clutch levers, checking and

lubricating ............................................6-30

Brake and shift pedals, checking and

lubricating ............................................6-29

Brake fluid, changing .............................6-26

Brake fluid level, checking......................6-25

Brake lever...............................................3-8

Brake lever free play, adjusting ..............6-22

Brake light switch (rear), adjusting .........6-23

Brake pads, checking.............................6-23

Brake pedal..............................................3-8

Brake pedal position, adjusting ..............6-22

C

Cables, checking and lubricating............6-28

Carburetor, adjusting .............................6-16

Care.........................................................7-1

Clock .......................................................3-5

Clutch lever..............................................3-7

Clutch lever free play, adjusting .............6-21

Conversion table......................................8-5

D

Dimmer switch .........................................3-6

Drive belt slack ......................................6-26

Adjusting ..........................................6-27

Checking..........................................6-26

E

Engine break-in ....................................... 5-5

Engine oil and oil filter cartridge............... 6-8

Engine stop switch................................... 3-6

Engine trouble warning light .................... 3-2

F

Front fork, checking............................... 6-31

Fuel......................................................... 3-9

Fuel cock............................................... 3-11

Fuel consumption, tips for reducing ......... 5-4

Fuel gauge .............................................. 3-4

Fuel level warning light ............................ 3-2

Fuel tank breather hose......................... 3-10

Fuel tank cap........................................... 3-9

Fuses, replacing.................................... 6-35

H

Handlebar switches ................................. 3-6

Headlight bulb, replacing ....................... 6-36

Helmet holder........................................ 3-13

High beam indicator light ......................... 3-2

Horn switch ............................................. 3-6

I

Identification numbers .............................9-1

Idling speed, adjusting........................... 6-16

Ignition circuit cut-off system.................. 3-16

Indicator and warning lights..................... 3-2

K

Key identification number ........................ 9-1

L

Light switch.............................................. 3-6

M

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

Model label ..............................................9-2

N

Neutral indicator light ...............................3-2

P

Panel, removing and installing..................6-6

Parking.....................................................5-6

Part locations ...........................................2-1

Pass switch..............................................3-6

Periodic maintenance and lubrication

chart ......................................................6-3

R

Rider seat ..............................................3-12

S

Safety information....................................1-1

Self-diagnosis device ...............................3-4

Shifting.....................................................5-3

Shift pedal................................................3-7

Shift points (for Switzerland only) .............5-4

Shock absorber assembly, adjusting......3-14

Sidestand...............................................3-15

Sidestand, checking and lubricating .......6-30

Spark plugs, checking..............................6-7

Specifications...........................................8-1

Speedometer unit.....................................3-3

Starter (choke) knob...............................3-12

Starting a warm engine............................5-3

Starting the engine...................................5-1

Start switch ..............................................3-7

Steering, checking..................................6-31