Virago xv535 Owner S Manual PDF

OWNER’S MANUAL
XV535
3BT-28199-E7
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EAU03338
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of an XV535, 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 XV535. 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 oth-
ers 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 EAU00005
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING 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.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
NOTE:
@
● 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
EAU03337
XV535
OWNER’S MANUAL
© 2000 by Yamaha Motor Co., Ltd.
1st Edition, July 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

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


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

GIVE SAFETY THE RIGHT OF WAY

1-
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

DESCRIPTION
2-
EAU00026
Left view
1. Headlight (page 6-31) 7. Shock absorber spring

2. Air filter element (page 6-11) preload adjusting ring (page 3-9)
3. Rider seat (page 3-8) 8. Main switch (page 3-1)
4. Owner’s tool kit (page 6-1) 9. Starter (choke) lever (page 3-6)
5. Helmet holder (page 3-9) 10. Shift pedal (page 3-4)
6. Passenger seat (page 3-7)
2-1
DESCRIPTION
Right view
11. Rear turn signal light (page 6-33) 14. Front turn signal light (page 6-33)
12. Fuel sub-tank 15. Brake pedal (page 3-4)
13. Fuel tank (page 3-5) 16. Battery (page 6-29)
2-2
DESCRIPTION
Controls and instruments
1. Clutch lever (page 3-3)

2. Speedometer unit (page 3-2)
3. Brake lever (page 3-4)
4. Throttle grip (page 6-14)
5. Right handlebar switches (page 3-3)
6. Left handlebar switches (page 3-2)
2-3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch ........................................................................................ 3-1

Indicator lights .................................................................................... 3-1
Speedometer unit .............................................................................. 3-2
Handlebar switches ............................................................................ 3-2
Clutch lever ........................................................................................ 3-3
Shift pedal .......................................................................................... 3-4
3
Brake lever ......................................................................................... 3-4
Brake pedal ........................................................................................ 3-4
Fuel tank cap ..................................................................................... 3-5
Fuel .................................................................................................... 3-5
Starter (choke) lever........................................................................... 3-6
Steering lock ..................................................................................... 3-7
Seats ................................................................................................. 3-7
Helmet holder..................................................................................... 3-9
Adjusting the shock absorber assemblies ......................................... 3-9
Sidestand ......................................................................................... 3-10
Ignition circuit cut-off system............................................................ 3-10


3-
EAU00027
3
1. Push. 1. High beam indicator light “ ”
2. Release. 2. Neutral indicator light “ ”
EAU00028
3. Turn. 3. Turn signal indicator light “ ”
Main switch
EAU00055 EAU00056
The main switch controls the ignition
P (Parking) Indicator lights
and lighting systems. The various main The taillight and auxiliary light are on,
switch positions are described below. but all other electrical systems are off. EAU00063
The key can be removed. High beam indicator light “ ”

EAU00036
The key must be pushed in, and then This indicator light comes on when the
ON
released before it can be turned to “P”. high beam of the headlight is switched
All electrical systems are supplied with
ECA00043 on.
power, and the engine can be started.
The key cannot be removed. CAUTION: EAU00061
@
Do not use the parking position for Neutral indicator light “ ”

EAU00038 an extended length of time, other- This indicator light comes on when the
OFF wise the battery may discharge. transmission is in the neutral position.
All electrical systems are off. The key @
can be removed. EAU00057
Turn signal indicator light “ ”

This indicator light flashes when the turn
signal switch is pushed to the left or right.
3-1

EAU00124
Turn signal switch

To signal a right-hand turn, push this
switch to the right. To signal a left-hand
turn, push this switch to the left. When
released, the switch returns to the cen-
ter position.
Since this model is equipped with a self-
3
canceling system, the turn signal lights
1. Tripmeter reset knob 1. Pass switch “ ” will self-cancel after the motorcycle has
2. Odometer 2. Dimmer switch traveled both about 150 m and for ap-
3. Tripmeter 3. Turn signal switch
4. Horn switch “ ” proximately 15 seconds. However, the
EAU00095
turn signal lights can also be canceled
Speedometer unit EAU00118
Handlebar switches manually by pushing the switch in after

The speedometer unit is equipped with
it has returned to the center position.
a speedometer, an odometer and a
EAU00119
tripmeter. The speedometer shows Pass switch “ ” NOTE:
@
riding speed. The odometer shows the Press this switch to flash the headlight. The self-canceling system only oper-
total distance traveled. The tripmeter ates when the motorcycle is moving, so
shows the distance traveled since it EAU00121 that the turn signal lights will not self-
was last set to zero with the reset knob. Dimmer switch cancel while you are stopped at an
The tripmeter can be used to estimate Set this switch to “ ” for the high intersection.
the distance that can be traveled with a beam and to “ ” for the low beam. @
full tank of fuel. This information will en- EAU00129
able you to plan future fuel stops. Horn switch “ ”

Press this switch to sound the horn.
3-2

EAU00143
Start switch “ ”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
@
See page 5-1 for starting instruc-

tions prior to starting the engine.
3 @
1. Engine stop switch EAU00149 1. Clutch lever

2. Light switch Fuel reserve switch “FUEL” EAU00152
3. Start switch “ ”
4. Fuel reserve switch “FUEL”
During normal operation, this switch Clutch lever
should be kept in the “ON” position. If The clutch lever is located at the left
EAU00138
Engine stop switch you run out of fuel while riding, set the handlebar grip. To disengage the
Set this switch to “ ” to stop the en- switch to “RES”, refuel as soon as pos- clutch, pull the lever toward the handle-
gine in case of an emergency, such as sible, and then set the switch back to bar grip. To engage the clutch, release
when the motorcycle overturns or “ON”. the lever. The lever should be pulled
when the throttle cable is stuck. rapidly and released slowly for smooth
NOTE:
@
clutch operation.
After switching to “RES”, approximately
EAU00134 The clutch lever is equipped with a
Light switch 2.5 L of fuel remain in the fuel tank.
@ clutch switch, which is part of the ignition
Set this switch to “ ” to turn on the circuit cut-off system. (See page 3-10
auxiliary light, meter lighting and tail- for an explanation of the ignition circuit
light. Set the switch to “ ” to turn on cut-off system.)
the headlight also.
3-3
3
1. Shift pedal 1. Brake lever 1. Brake pedal
EAU00157 EAU00158 EAU00162
Shift pedal Brake lever Brake pedal

The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of
side of the engine and is used in com- handlebar grip. To apply the front the motorcycle. To apply the rear
bination with the clutch lever when brake, pull the lever toward the handle- brake, press down on the brake pedal.
shifting the gears of the 5-speed con- bar grip.
stant-mesh transmission equipped on
this motorcycle.
3-4

NOTE:
_
The fuel tank cap cannot be closed un-

less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
_
EWA00025
_
WARNING
3 Make sure that the fuel tank cap is
1. Unlock. properly closed before riding. 1. Fuel tank filler tube
_
2. Fuel level
EAU03712
Fuel tank cap EAU01183
Fuel
To open the fuel tank cap Make sure that there is sufficient fuel in
Insert the key into the lock and turn it the tank. Fill the fuel tank to the bottom
1/4 turn clockwise. The lock will be re- of the filler tube as shown in the illustra-
leased and the fuel tank cap can be tion.
EW000130
opened.
@
WARNING
To close the fuel tank cap ● Do not overfill the fuel tank, oth-
1. Push the fuel tank cap into posi- erwise it may overflow when the
tion with the key inserted in the fuel warms up and expands.
● Avoid spilling fuel on the hot
lock.
2. Turn the key counterclockwise to engine.
@
the original position, and then re-

move it.
3-5

EAU00185
CAUTION:
@
Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es or plastic parts.
@
EAU00191 3
1. Starter (choke) lever
Recommended fuel:
EAU02976
Regular unleaded gasoline with a
research octane number of 91 or
Starter (choke) lever
Starting a cold engine requires a richer
higher
Fuel tank capacity: air-fuel mixture, which is supplied by
Total amount: the starter (choke).
Move the lever in direction a to turn on
13.5 L
Reserve amount: the starter (choke).
2.5 L Move the lever in direction b to turn off
the starter (choke).
NOTE:
@
If knocking (or pinging) occurs, use

gasoline of a different brand or with a
higher octane grade.
@
3-6

To unlock the steering
1. Open the steering lock cover, and
then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it moves
out, and then release it.
3. Remove the key, and then close
3 the lock cover.
1. Steering lock 1. Seat lock
2. Unlock.
EAU02934
Steering lock EAU02940
Seats
To lock the steering
1. Turn the handlebar all the way to Passenger seat
right. To remove the passenger seat
2. Open the steering lock cover, and 1. Insert the key into the seat lock,
then insert the key. and then turn it clockwise.
3. Turn the key 1/8 turn counter- 2. Pull the passenger seat off.
clockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn
clockwise.
4. Check that the steering is locked,
remove the key, and then close
the lock cover.
3-7
3
1. Projection 1. Bolt (× 2) 1. Seat holder (× 2)
2. Seat holder 2. Projection (× 2)
Rider seat
To install the passenger seat To remove the rider seat To install the rider seat
1. Insert the projection on the rear of 1. Remove the passenger seat. 1. Insert the projections on the front
the passenger seat into the seat 2. Remove the bolts, and then pull of the rider seat into the seat hold-
holder as shown, and then push the rider seat off. ers as shown, place the seat in the
the front of the seat down to lock it original position, and then tighten
in place. the bolts.
2. Turn the key counterclockwise, 2. Install the passenger seat.
and then remove it.
NOTE:
@
Make sure that the seats are properly

secured before riding.
@
3-8

EAU00300
Adjusting the shock absorber

assemblies
Each shock absorber assembly is
equipped with a spring preload adjust-
ing ring.
EC000015
CAUTION:
3 @
Never attempt to turn an adjusting

1. Unlock. mechanism beyond the maximum 1. Spring preload adjusting ring
2. Position indicator
EAU00260
or minimum settings.
Helmet holder @
Adjust the spring preload as follows.
EW000040
To open the helmet holder, insert the To increase the spring preload and
WARNING
key into the lock, and then turn the key @
thereby harden the suspension, turn
Always adjust both shock absorber the adjusting ring on each shock ab-
as shown.
assemblies equally, otherwise poor sorber assembly in direction a. To de-
To lock the helmet holder, place it in
handling and loss of stability may crease the spring preload and thereby
the original position, and then remove
result. soften the suspension, turn the adjust-
the key. @
EW000030 ing ring on each shock absorber as-

WARNING sembly in direction b.
@
Never ride with a helmet attached to

NOTE:
the helmet holder, since the helmet @
Align the appropriate notch in the ad-

may hit objects, causing loss of justing ring with the position indicator
control and possibly an accident. on the shock absorber.
@
@
CI-01E
Minimum
Standard Maximum (hard)
(soft)
Setting 1 2 3 4 5
3-9

EAU00330 EW000044 EAU03720
Sidestand WARNING Ignition circuit cut-off system

@
The sidestand is located on the left side The motorcycle must not be ridden The ignition circuit cut-off system (com-
of the frame. Raise the sidestand or with the sidestand down, or if the prising the sidestand switch, clutch
lower it with your foot while holding the sidestand cannot be properly switch and neutral switch) has the fol-
motorcycle upright. moved up (or does not stay up), oth- lowing functions.
erwise the sidestand could contact ● It prevents starting when the trans-
NOTE: mission is in gear and the side-
the ground and distract the opera-
@
The built-in sidestand switch is part of 3

tor, resulting in a possible loss of stand is up, but the clutch lever is
the ignition circuit cut-off system, which
control. Yamaha’s ignition circuit not pulled.
cuts the ignition in certain situations.
cut-off system has been designed to ● It prevents starting when the trans-
(See further down for an explanation of
assist the operator in fulfilling the mission is in gear and the clutch
the ignition circuit cut-off system.)
@
responsibility of raising the side- lever is pulled, but the sidestand is
stand before starting off. Therefore, still down.
check this system regularly as de- ● It cuts the running engine when
scribed below and have a Yamaha the transmission is in gear and the
dealer repair it if it does not function sidestand is moved down.
properly. Periodically check the operation of the
@
ignition circuit cut-off system according
to the following procedure.
EW000045
_
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
_
3-10

CD-01E
With the engine turned off: NOTE:

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

4-
EAU01114
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 inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list

CO-01E
ITEM CHECKS PAGE

• Check fuel level in fuel tank.
Fuel • Refuel if necessary. 3-5–3-6
• Check fuel line for leakage.
4 • Check oil level in engine.
Engine oil • If necessary, add recommended oil to specified level. 6-7
• Check vehicle for oil leakage.
Final gear oil • Check vehicle for oil leakage. 6-9–6-10
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
Front brake • Adjust if necessary. 6-19, 6-21–6-23
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
Rear brake • Check pedal free play. 6-19–6-23
• Adjust if necessary.
• Lubricate cable if necessary.
Clutch 6-18
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Lubricate throttle grip, housing and cables if necessary.
Throttle grip 6-14, 6-24
• Check free play.
• If necessary, have Yamaha dealer make adjustment.
4-1
ITEM CHECKS PAGE
Control cables 6-24
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires 6-15–6-17
• Check air pressure.
• Correct if necessary.
Brake and shift pedals 6-25
• Lubricate pedal pivoting points if necessary.
Brake and clutch levers 6-25
• Lubricate lever pivoting points if necessary.
Sidestand
6-25–6-26
4
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
—
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-10
• If system is defective, have Yamaha dealer check vehicle.
• Check fluid level.
Battery 6-29–6-30
• Fill with distilled water if necessary.
NOTE:
@
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
@
EWA00033
@
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
@
4-2

OPERATION AND IMPORTANT RIDING POINTS
Starting a cold engine ....................................................................... 5-1

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


5-
EAU00372
EAU00373 EAU02997*
1. Turn the key to “ON” and make
WARNING Starting a cold engine sure that the engine stop switch is
@
● Become thoroughly familiar In order for the ignition circuit cut-off set to “ ”.
with all operating controls and system to enable starting, one of the 2. Shift the transmission into the neu-
their functions before riding. following conditions must be met: tral position.
Consult a Yamaha dealer re- ● The transmission is in the neutral
garding any control or function position. NOTE:

@
● The transmission is in gear with When the transmission is in the neutral

that you do not thoroughly un-
the clutch lever pulled and the position, the neutral indicator light
derstand.
sidestand up. should be on, otherwise have a
● Never start the engine or oper-
EW000054 Yamaha dealer check the electrical
ate it in a closed area for any
WARNING circuit.
length of time. Exhaust fumes @
5
@
● Before starting the engine,

are poisonous, and inhaling 3. Turn the starter (choke) on and
them can cause loss of con- check the function of the igni- completely close the throttle. (See
sciousness and death within a tion circuit cut-off system ac- page 3-6 for starter (choke) opera-
short time. Always make sure cording to the procedure tion.)
that there is adequate ventila- described on page 3-11. 4. Start the engine by pushing the
● Never ride with the sidestand
tion. start switch.
● Before starting out, make sure
down.
that the sidestand is up. If the
@
NOTE:
@
If the engine fails to start, release the

sidestand is not raised com-
start switch, wait a few seconds, and
pletely, it could contact the
then try again. Each starting attempt
ground and distract the opera-
should be as short as possible to pre-
tor, resulting in a possible loss
serve the battery. Do not crank the en-
of control.
@
gine more than 10 seconds on any one
attempt.
@
5-1

5. After starting the engine, move the EAU01258
starter (choke) lever back halfway. Starting a warm engine

ECA00045 Follow the same procedure as for start-
CAUTION: ing a cold engine with the exception
@
For maximum engine life, never ac- that the starter (choke) is not required
celerate hard when the engine is when the engine is warm.
cold!
@
6. When the engine is warm, turn the

starter (choke) off.
NOTE:
@
The engine is warm when it responds

5
normally to the throttle with the starter
(choke) turned off.
@
5-2

EC000048 EAU02941
CAUTION: Recommended shift points

(for Switzerland only)
@
● Even with the transmission in

the neutral position, do not The recommended shift points during
coast for long periods of time acceleration are shown in the table
with the engine off, and do not below.
CF-01E
tow the motorcycle for long dis- Shift point
tances. The transmission is (km/h)
properly lubricated only when 1st → 2nd 23
1. Shift pedal 2nd → 3rd 36
N. Neutral position
the engine is running. Inade-
3rd → 4th 50
quate lubrication may damage
EAU00423 4th → 5th 60
Shifting the transmission.
5
● Always use the clutch while NOTE:
Shifting gears lets you control the @
changing gears to avoid dam- When shifting down two gears at a

amount of engine power available for
starting off, accelerating, climbing hills, aging the engine, transmission, time, reduce the speed accordingly
etc. and drive train, which are not (e.g., down to 35 km/h when shifting
designed to withstand the from 4th to 2nd gear).
The gear positions are shown in the @
illustration. shock of forced shifting.

@
NOTE:
@
To shift the transmission into the neu-

tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
5-3

EAU00424 EAU00436 EAU00444*
Tips for reducing fuel Engine break-in 0–150 km

consumption There is never a more important period ● Avoid prolonged operation above
Fuel consumption depends largely on in the life of your engine than the period 1/3 throttle.
between 0 and 1,000 km. For this rea- ● After every hour of operation, stop
your riding style. Consider the following
tips to reduce fuel consumption: son, you should read the following ma- the engine, and then let it cool for
● Thoroughly warm up the engine. terial carefully. five to ten minutes.
Since the engine is brand new, do not ● Vary the engine speed from time
● Turn the starter (choke) off as
soon as possible. put an excessive load on it for the first to time. Do not operate the engine
● Shift up swiftly, and avoid high en- 1,000 km. The various parts in the en- at one set throttle position.
gine speeds during acceleration. gine wear and polish themselves to the
● Do not rev the engine while shift- correct operating clearances. During 150–500 km
ing down, and avoid high engine this period, prolonged full-throttle oper- ● Avoid prolonged operation above 5
speeds with no load on the engine. ation or any condition that might result 1/2 throttle.
● Turn the engine off instead of let- in engine overheating must be avoided. ● Rev the engine freely through the
ting it idle for an extended length gears, but do not use full throttle at
of time (e.g., in traffic jams, at traf- any time.
fic lights or at railroad crossings).
500–1,000 km
Avoid prolonged operation above
3/4 throttle.
EC000056*
CAUTION:
@
After 1,000 km of operation, the en-

gine oil and final gear oil must be
changed, and the oil filter element
replaced.
@
5-4

1,000 km and beyond EAU00460
Avoid prolonged full-throttle operation. Parking

Vary the speed occasionally. When parking, stop the engine, and
EC000049 then remove the key from the main
CAUTION: switch.
@
EW000058
If any engine trouble should occur
WARNING
during the engine break-in period, @
immediately have a Yamaha dealer ● Since the engine and exhaust

check the vehicle. system can become very hot,
@ park in a place where pedestri-
ans or children are not likely to
touch them.
5 ● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
5-5
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1 Checking and lubricating the cables .................. 6-23
Periodic maintenance and lubrication chart .........6-2 Checking and lubricating the throttle
Checking the spark plugs ....................................6-5 grip and cable .................................................. 6-24
Engine oil and oil filter element ............................6-7 Checking and lubricating the brake and
Final gear oil ........................................................6-9 shift pedals ...................................................... 6-25
Cleaning the air filter element ............................6-11 Checking and lubricating the brake and
clutch levers ..................................................... 6-25
Adjusting the carburetors....................................6-13
Checking and lubricating the sidestand ............. 6-25
Adjusting the engine idling speed .......................6-13
Lubricating the rear suspension ........................ 6-26
Adjusting the throttle cable free play...................6-14
Checking the front fork ....................................... 6-27
Adjusting the valve clearance .............................6-14
Checking the steering ........................................ 6-27
Tires ...................................................................6-15
Checking the wheel bearings ............................. 6-28
Spoke wheels .....................................................6-17
Battery ............................................................... 6-29 6
Adjusting the clutch lever free play ....................6-18
Replacing the fuses .......................................... 6-31
Adjusting the brake lever free play......................6-19
Replacing the headlight bulb.............................. 6-31
Adjusting the brake pedal position and
free play ...........................................................6-19 Replacing a turn signal light bulb or the
tail/brake light bulb ........................................... 6-33
Adjusting the rear brake light switch ...................6-21
Supporting the motorcycle ................................ 6-33
Checking the front brake pads and rear
brake shoes .....................................................6-21 Front wheel ....................................................... 6-34
Checking the brake fluid level ............................6-22 Rear wheel ........................................................ 6-35
Changing the brake fluid.....................................6-23 Troubleshooting.................................................. 6-37
Troubleshooting chart ........................................ 6-38


6-
EAU00462
EAU00464
NOTE:
Safety is an obligation of the owner. _
If you do not have the tools or experi-

Periodic inspection, adjustment and lu-
ence required for a particular job, have
brication will keep your vehicle in the
a Yamaha dealer perform it for you.
safest and most efficient condition pos- _
EW000063
sible. The most important points of in-
spection, adjustment, and lubrication _
WARNING
are explained on the following pages. Modifications not approved by
The intervals given in the periodic Yamaha may cause loss of perfor-
maintenance and lubrication chart 1. Owner’s tool kit mance and render the vehicle un-
should be simply considered as a gen- EAU03713
safe for use. Consult a Yamaha
eral guide under normal riding condi- Owner’s tool kit dealer before attempting any chang-
tions. However, DEPENDING ON THE The tool kit is located under the pas- es.
_
WEATHER, TERRAIN, GEOGRAPHI- senger seat. (See page 3-7 for passen-
6 CAL LOCATION, AND INDIVIDUAL ger seat removal procedures.)
USE, THE MAINTENANCE INTER- The service information included in this
VALS MAY NEED TO BE SHORT- manual and the tools provided in the
ENED. owner’s tool kit are intended to assist
EW000060
you in the performance of preventive
@
WARNING maintenance and minor repairs. How-
If you are not familiar with motor- ever, additional tools such as a torque
cycle maintenance work, have a wrench may be necessary to perform
Yamaha dealer do it for you. certain maintenance work correctly.
@
6-1

EAU03685
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-03E
ODOMETER READING (× 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √
2 * Fuel filter • Check condition. √ √
• Check condition.
√ √
3 Spark plugs • Clean and regap.
• Replace. √ √ 6
• Check valve clearance.
4 * Valves √ √ √ √
• Adjust.
• Clean. √ √
5 Air filter element
• Replace. √ √
• Check electrolyte level and specific gravity.
6 * Battery √ √ √ √ √
• Make sure that the breather hose is properly routed.
7 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage.
√ √ √ √ √ √
8 (See NOTE on page 6-4.)
* Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation and adjust brake pedal freeplay. √ √ √ √ √ √
9 * Rear brake • Replace brake shoes. Whenever worn to the limit
6-2

1 10 20 30 40 CHECK
• Check for cracks or damage. √ √ √ √ √
10 * Brake hose • Replace. (See NOTE on page 6-4.) Every 4 years
• Check runout, spoke tightness and for damage.
11 * Wheels √ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
12 * Tires √ √ √ √
• Check air pressure.
• Correct if necessary.
13 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check operation and for excessive play. √ √ √ √
14 * Swingarm • Lubricate with molybdenum disulfide grease. Every 50,000 km
• Check bearing play and steering for roughness. √ √ √ √ √
15 * Steering bearings • Lubricate with lithium-soap-based grease. Every 20,000 km
6
16 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
17 Sidestand √ √ √ √ √
• Lubricate.
18 * Sidestand switch • Check operation. √ √ √ √ √ √
19 * Front fork • Check operation and for oil leakage. √ √ √ √
Rear shock absorber
20 * assemblies • Check operation and shock absorbers for oil leakage. √ √ √ √
• Check starter (choke) operation.

21 * Carburetors √ √ √ √ √ √
• Adjust engine idling speed and synchronization.
22 Engine oil • Change. √ √ √ √ √ √
23 Engine oil filter element • Replace. √ √ √
6-3

1 10 20 30 40 CHECK
• Check oil level and vehicle for oil leakage. √ √ √
24 Final gear oil
• Change. √ √ √
Front and rear brake
25 * • Check operation. √ √ √ √ √ √
switches
26 Moving parts and cables • Lubricate. √ √ √ √ √
Lights, signals and • Check operation.
27 * switches √ √ √ √ √ √
• Adjust headlight beam.
EAU03541
NOTE:
@
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. 6
• Replace the brake hoses every four years and if cracked or damaged.
@
6-4

To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
1. Spark plug cover 1. Spark plug wrench NOTE:
@
2. Screw (× 2) If any spark plug shows a distinctly dif-

3. Remove the spark plug as shown,
EAU01486
with the spark plug wrench includ- ferent color, the engine could be defec-
Checking the spark plugs tive. Do not attempt to diagnose such
ed in the owner’s tool kit.
The spark plugs are important engine problems yourself. Instead, have a
6 components, which are easy to check. Yamaha dealer check the motorcycle.
Since heat and deposits will cause any @
spark plug to slowly erode, the spark 3. Check each spark plug for elec-
trode erosion and excessive car-
plugs should be removed and checked
in accordance with the periodic mainte- bon or other deposits, and replace
nance and lubrication chart. In addition, it if necessary.
the condition of the spark plugs can re-
veal the condition of the engine. Specified spark plug:
BPR6ES (NGK) or
W20EPR-U (DENSO)
To remove a spark plug
1. Remove the appropriate spark
plug cover (rear right or front left)
by removing the screws.
2. Remove the spark plug cap.
6-5

Tightening torque:
Spark plug:
20 Nm (2.0 m·kg)
NOTE:
@
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
a. Spark plug gap past finger tight. However, the spark
plug should be tightened to the speci-
To install a spark plug
fied torque as soon as possible.
1. Measure the spark plug gap with a @
wire thickness gauge and, if nec- 4. Install the spark plug cap.
essary, adjust the gap to specifica- 5. Install the spark plug cover by in-
tion. stalling the screws. 6
Spark plug gap:

0.7–0.8 mm
2. Clean the surface of the spark

plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
6-6

EAU02942
Engine oil and oil filter

element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
1. Engine oil level check window 1. Engine oil filler cap
2. Maximum level mark
To check the engine oil level 3. Minimum level mark To change the engine oil
1. Place the motorcycle on a level (with or without oil filter element
3. Wait a few minutes until the oil set-
surface and hold it in an upright replacement)
tles, and then check the oil level
position. 1. Start the engine, warm it up for
6 through the check window located
several minutes, and then turn it
NOTE: at the bottom-left side of the crank-
@
off.
Make sure that the motorcycle is posi- case.
2. Place an oil pan under the engine
tioned straight up when checking the oil
NOTE: to collect the used oil.
level. A slight tilt to the side can result in @
The engine oil should be between the

a false reading.
@ minimum and maximum level marks.
2. Start the engine, warm it up for @
4. If the engine oil is below the mini-

several minutes, and then turn it
mum level mark, add sufficient oil
off.
of the recommended type to raise
it to the correct level.
6-7
1. Engine oil drain bolt 1. Oil filter element cover 1. O-ring

2. Bolt (× 3) 2. Oil filter element
3. Remove the engine oil filler cap
and drain bolt to drain the oil from 4. Remove the oil filter element cover 5. Remove and replace the oil filter
the crankcase. by removing the bolts. element and O-ring.
6. Install the oil filter element cover
NOTE:
@ by installing the bolts and tighten- 6
Skip steps 4–6 if the oil filter element is ing them to the specified torque.
not being replaced.
@
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kg)
6-8

EAU03714
NOTE:
@
Make sure that the O-ring is properly

Recommended engine oil: Final gear oil
See page 8-1. The final gear case must be checked
seated.
@ Oil quantity: for oil leakage before each ride. If any
7. Install the engine oil drain bolt, and Without oil filter element leakage is found, have a Yamaha deal-
then tighten it to the specified replacement: er check and repair the motorcycle. In
torque. 2.6 L addition, the final gear oil level must be
With oil filter element checked and the oil changed as follows
Tightening torque: replacement: at the intervals specified in the periodic
Engine oil drain bolt: 2.8 L maintenance and lubrication chart.
43 Nm (4.3 m·kg) Total amount (dry engine): EW000066
3.2 L WARNING
8. Add the specified amount of the _
● Make sure that no foreign mate-

recommended engine oil, and EC000067
rial enters the final gear case.
then install and tighten the oil filler CAUTION:
6 @
● Make sure that no oil gets on
cap. If the oil level warning light flickers
the tire or wheel.
or remains on, immediately turn the _
engine off and have a Yamaha deal-

er check the vehicle.
@
9. 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.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
6-9

NOTE:
_
Recommended final gear oil:

The oil level should be at the brim of
Hypoid gear oil SAE 80 (API GL4)
the filler hole.
_ or multi-grade hypoid gear oil
3. If the oil is below the brim of the fill- SAE 80W-90
er hole, add sufficient oil of the rec- Oil quantity:
ommended type to raise it to the 0.19 L
correct level.
NOTE:
_
1. Final gear oil filler bolt To change the final gear oil GL4 is a quality rating. Hypoid gear oils
2. Correct oil level 1. Place an oil pan under the final rated GL5 or GL6 may also be used.
3. Final gear oil drain bolt gear case to collect the used oil.
_
5. Install and tighten the filler bolt.

To check the final gear oil level 2. Remove the oil filler bolt and drain
6. Check the final gear case for oil
1. Place the motorcycle on a level bolt to drain the oil from the final
leakage. If oil is leaking, check for
surface and hold it in an upright gear case. 6
the cause.
position. 3. Install the final gear oil drain bolt,
and then tighten it to the specified
NOTE:
_
torque.
● The final gear oil level must be
checked on a cold engine.
Tightening torque:
● Make sure that the motorcycle is
Final gear oil drain bolt:
positioned straight up when 23 Nm (2.3 m·kg)
checking the oil level. A slight tilt to
the side can result in a false 4. Add the recommended final gear
reading. oil to the brim of the filler hole.
_
2. Remove the oil filler bolt, and then

check the oil level in the final gear
case.
6-10
1. Fuel tank 1. Screw 1. Air filter case cover

2. Bolt (× 3) 2. Tab
3. Lift the front of the fuel tank to po- 3. Holder
EAU03715
sition it away from the air filter 4. Air filter element
Cleaning the air filter element
case. (Do not remove the fuel 5. Slide the air filter case cover so as
The air filter element should be cleaned
tank!) to unhook the tab on the rear of
6 at the intervals specified in the periodic EW000071
maintenance and lubrication chart. the cover from the holder on the
WARNING
Clean the air filter element more fre- _
frame, and then lift the air filter
● Make sure that the fuel tank is
quently if you are riding in unusually case cover without removing it.
well supported.
wet or dusty areas.
● Do not tilt or pull the fuel tank
1. Remove the seats. (See page 3-7
too much, otherwise the fuel
for seat removal and installation
hoses may come loose, which
procedures.)
could cause fuel leakage.
2. Remove the fuel tank bolts. _
4. Remove the air filter case cover

screw.
6-11

EC000082
CAUTION:
_
● Make sure that the air filter ele-

ment is properly seated in the
air filter case.
● The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
1. Air filter element 1. Washer
become excessively worn. 2. Rubber damper
6. Pull the air filter element out. _
3. Spacer
9. Place the air filter case cover in the
7. Lightly tap the air filter element to
original position, and then install EW000131
remove most of the dust and dirt,
the screw. WARNING
and then blow the remaining dirt _
10. Install the fuel tank by installing the Make sure that the fuel hoses and 6
out with compressed air as shown.
bolts. vacuum hose are properly connect-
If the air filter element is damaged,
ed and routed, and not pinched. Re-
replace it.
place any damaged hoses.
8. Insert the air filter element into the _
EC000086
air filter case.
CAUTION:
_
When installing the fuel tank bolts,

make sure that the washers, rubber
dampers and spacers are posi-
tioned properly.
_
11. Install the seats.
6-12

EAU00630 EAU01168
Adjusting the carburetors Adjusting the engine idling

The carburetors are important parts of speed
the engine and require very sophisti- The engine idling speed must be
cated adjustment. Therefore, most car- checked and, if necessary, adjusted as
buretor adjustments should be left to a follows at the intervals specified in the
Yamaha dealer, who has the neces- periodic maintenance and lubrication
sary professional knowledge and expe- chart.
rience. The adjustment described in
the following section, however, may be NOTE:
@
1. Throttle stop screw
serviced by the owner as part of routine A diagnostic tachometer is needed to
3. Check the engine idling speed
maintenance. make this adjustment.
@
and, if necessary, adjust it to spec-
EC000095
1. Attach the tachometer to the spark ification by turning the throttle stop
CAUTION: plug lead. screw. To increase the engine
@
6 The carburetors have been set and 2. Start the engine and warm it up idling speed, turn the screw in di-
extensively tested at the Yamaha for several minutes at 1,000– rection a. To decrease the engine
factory. Changing these settings 2,000 r/min while occasionally rev- idling speed, turn the screw in
without sufficient technical knowl- ving it to 4,000–5,000 r/min. direction b.
edge may result in poor perfor-
mance of or damage to the engine. NOTE:
@
Engine idling speed:
@ The engine is warm when it quickly re-
1,150–1,250 r/min
sponds to the throttle.
@
NOTE:
@
If the specified idling speed cannot be

obtained as described above, have a
Yamaha dealer make the adjustment.
@
6-13

EAU00637
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
measure 3–5 mm at the throttle grip. 6
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
6-14

EAU03362 CE-01E EWA00012
Tires Tire air pressure

WARNING
(measured on cold tires) @
To maximize the performance, durabil- Because loading has an enormous

Load* Front Rear
ity, and safe operation of your motor- 200 kPa 225 kPa impact on the handling, braking,
cycle, note the following points Up to 90 kg 2.00 kg/cm2 2.25 kg/cm2 performance and safety characteris-
2.00 bar 2.25 bar
regarding the specified tires. tics of your motorcycle, you should
200 kPa 250 kPa
90 kg–maximum 2.00 kg/cm2 2.50 kg/cm2 keep the following precautions in
Tire air pressure 2.00 bar 2.50 bar mind.
The tire air pressure should be CE-07E
● NEVER OVERLOAD THE
220 kg (except for A)
checked and, if necessary, adjusted Maximum load*
218 kg (for A) MOTORCYCLE! Operation of
before each ride. * Total weight of rider, passenger, cargo and an overloaded motorcycle may
EW000082 accessories
result in tire damage, loss of
@
WARNING control, or severe injury. Make
● The tire air pressure must be sure that the total weight of rid-
6 checked and adjusted on cold er, passenger, cargo, and ac-
tires (i.e., when the temperature cessories does not exceed the
of the tires equals the ambient specified maximum load for the
temperature). vehicle.
● The tire air pressure must be
● Do not carry along loosely
adjusted in accordance with the packed items, which can shift
riding speed and with the total during a ride.
weight of rider, passenger, car- ● Securely pack the heaviest
go, and accessories approved items close to the center of the
for this model. motorcycle and distribute the
@
weight evenly on both sides.
6-15

● Adjust the suspension and tire EW000079
air pressure with regard to the @

WARNING
load. ● Have a Yamaha dealer replace
● Check the tire condition and air excessively worn tires. Besides
pressure before each ride. being illegal, operating the
@
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
1. Sidewall
● The replacement of all wheel-
a. Tire tread depth
and brake-related parts, includ-
Tire inspection ing the tires, should be left to a
The tires must be checked before each Yamaha dealer, who has the
ride. If the center tread depth reaches necessary professional knowl-
the specified limit, if the tire has a nail edge and experience. 6
or glass fragments in it, or if the side- @
wall is cracked, have a Yamaha dealer

replace the tire immediately.
CE-08E
Minimum tire tread depth
1.6 mm
(front and rear)
NOTE:
@
The tire tread depth limits may differ

from country to country. Always comply
with the local regulations.
@
6-16

Tire information EAU00681 EAU00685
This motorcycle is equipped with tube WARNING Spoke wheels

@
tires. ● Have a Yamaha dealer replace To maximize the performance, durabil-

EW000078 excessively worn tires. Besides ity, and safe operation of your motor-
WARNING being illegal, operating the cycle, note the following points
@
● The front and rear tires should motorcycle with excessively regarding the specified wheels.
be of the same make and de- worn tires decreases riding sta- ● The wheel rims should be checked
sign, otherwise the handling bility and can lead to loss of for cracks, bends or warpage, and
characteristics of the motor- control. the spokes for looseness or dam-
cycle cannot be guaranteed. ● The replacement of all wheel- age before each ride. If any dam-
● After extensive tests, only the and brake-related parts, includ- age is found, have a Yamaha
tires listed below have been ap- ing the tires, should be left to a dealer replace the wheel. Do not
proved for this model by Yamaha dealer, who has the attempt even the smallest repair to
Yamaha Motor Co., Ltd. necessary professional knowl- the wheel. A deformed or cracked
6 @
edge and experience. wheel must be replaced.

CE-10E
FRONT
● It is not recommended to patch ● The wheel should be balanced
Manufacturer Size Model whenever either the tire or wheel
a punctured tube. If unavoid-
Bridgestone 3.00-19 49S L303A has been changed or replaced. An
able, however, patch the tube
Dunlop 3.00-19 49S F14G
very carefully and replace it as unbalanced wheel can result in
REAR
soon as possible with a high- poor performance, adverse han-
Manufacturer Size Model dling characteristics, and a short-
quality product.
Bridgestone 140/90-15 M/C 70S G508 @
ened tire life.
Dunlop 140/90-15 M/C 70S K425
● Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
6-17

7. Tighten the locknut at the clutch
lever and the crankcase.
1. Locknut 1. Locknut
2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut
c. Clutch lever free play
3. If the specified clutch lever free
EAU00694
play could be obtained as de-
Adjusting the clutch lever free
scribed above, tighten the locknut
play and skip the rest of the procedure, 6
The clutch lever free play should mea- otherwise proceed as follows.
sure 10–15 mm as shown. Periodically
4. Fully turn the adjusting bolt at the
check the clutch lever free play and, if clutch lever in direction a to loos-
necessary, adjust it as follows. en the clutch cable.
1. Loosen the locknut at the clutch
5. Loosen the locknut at the crank-
lever. case.
2. To increase the clutch lever free 6. To increase the clutch lever free
play, turn the adjusting bolt in di-
play, turn the adjusting nut in di-
rection a. To decrease the clutch rection a. To decrease the clutch
lever free play, turn the adjusting lever free play, turn the adjusting
bolt in direction b.
nut in direction b.
6-18

3. Tighten the locknut. EAU00711
EW000099 Adjusting the brake pedal

@
WARNING position and free play
EW000104
● After adjusting the brake lever
free play, check the free play @
WARNING
and make sure that the brake is It is advisable to have a Yamaha
working properly. dealer make these adjustments.
@
● A soft or spongy feeling in the

brake lever can indicate the NOTE:
@
1. Brake lever free play adjusting bolt

presence of air in the hydraulic The brake pedal position should be ad-
2. Locknut justed before adjusting the brake pedal
c. Brake lever free play system. If there is air in the hy-
draulic system, have a Yamaha free play.
EAU00696 @
Adjusting the brake lever free dealer bleed the system before
play operating the motorcycle. Air in
6 the hydraulic system will dimin-
The brake lever free play should mea-
sure 2–5 mm as shown. Periodically ish the braking performance,
check the brake lever free play and, if which may result in loss of con-
necessary, adjust it as follows. trol and an accident.
@
1. Loosen the locknut at the brake

lever.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.
6-19
1. Footrest 1. Brake pedal position adjusting bolt 1. Brake pedal free play adjusting nut
2. Distance between brake pedal and footrest 2. Locknut
a. Brake pedal free play Brake pedal free play
1. Loosen the locknut at the brake The brake pedal free play should mea-
Brake pedal position pedal. sure 20–30 mm at the brake pedal end.
The brake pedal should be positioned 2. To raise the brake pedal, turn the Periodically check the brake pedal free
approximately 38 mm above the top of adjusting bolt in direction a. To 6
play and, if necessary, adjust it as
the footrest as shown. Periodically lower the brake pedal, turn the ad- follows.
check the brake pedal position and, if justing bolt in direction b. To increase the brake pedal free play,
necessary, adjust it as follows. 3. Tighten the locknut. turn the adjusting nut at the brake rod
EW000105
in direction a. To decrease the brake
@
WARNING pedal free play, turn the adjusting nut in
After adjusting the brake pedal direction b.
height, the brake pedal free play
must be adjusted.
@
6-20

EAU00720
Front
Checking the front brake pads
and rear brake shoes
The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Rear brake light switch 1. Front brake pad wear indicator groove (× 2)
2. Rear brake light switch adjusting nut
EAU01119
EAU00713 Front brake pads

Adjusting the rear brake light Each front brake pad is provided with
switch wear indicator grooves, which allow
6 The rear brake light switch, which is ac- you to check the brake pad wear with-
tivated by the brake pedal, is properly out having to disassemble the brake.
adjusted when the brake light comes To check the brake pad wear, check
on just before braking takes effect. If the wear indicator grooves. If a brake
necessary, adjust the brake light switch pad has worn to the point that the wear
as follows. indicators have almost disappeared,
Turn the adjusting nut while holding the have a Yamaha dealer replace the
rear brake light switch in place. To brake pads as a set.
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.
6-21

Rear Observe these precautions:
● When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
● Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
1. Rear brake shoe wear limit 1. Minimum level mark
2. Rear brake shoe wear indicator mance.
EAU00732
EAU00727 Checking the brake fluid level

Rear brake shoes Recommended brake fluid: DOT 4
Insufficient brake fluid may allow air to
The rear brake is provided with a wear
enter the brake system, possibly caus-
indicator, which allows you to check the NOTE:
ing it to become ineffective.
@
If DOT 4 is not available, DOT 3 can be 6

brake shoe wear without having to dis-
Before riding, check that the brake fluid used.
assemble the brake. To check the
is above the minimum level mark and @
brake shoe wear, check the position of ● Refill with the same type of brake
replenish if necessary. A low brake flu-
the wear indicator while applying the fluid. Mixing fluids may result in a
id level may indicate worn brake pads
brake. If a brake shoe has worn to the harmful chemical reaction and
and/or brake system leakage. If the
point that the wear indicator reaches lead to poor braking performance.
brake level is low, be sure to check the
the wear limit line, have a Yamaha ● Be careful that water does not en-
brake pads for wear and the brake sys-
dealer replace the brake shoes as a ter the master cylinder when refill-
tem for leakage.
set. ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
6-22

● Brake fluid may deteriorate paint- EAU03238 EAU02962
ed surfaces or plastic parts. Al- Changing the brake fluid Checking and lubricating the
ways clean up spilled fluid Have a Yamaha dealer change the cables
immediately. brake fluid at the intervals specified in The operation of all control cables and
● As the brake pads wear, it is nor-
the periodic maintenance and lubrica- the condition of the cables should be
mal for the brake fluid level to tion chart. In addition, have the oil seals checked before each ride, and the ca-
gradually go down. However, if the of the brake master cylinder and caliper bles and cable ends should be lubricat-
brake fluid level goes down sud- as well as the brake hose replaced at ed if necessary. If a cable is damaged
denly, have a Yamaha dealer the intervals listed below or whenever it or does not move smoothly, have a
check the cause. is damaged or leaking. Yamaha dealer check or replace it.
● Oil seals: Replace every two
years. Recommended lubricant:
● Brake hose: Replace every four Engine oil
years.
EW000112
6
@
WARNING
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
@
6-23

EAU03209
Checking and lubricating the Recommended lubricant:

throttle grip and cable Throttle cable:
The operation of the throttle grip and Engine oil
the condition of the throttle cable Throttle grip housing and grip:
should be checked before each ride, Lithium-soap-based grease
and the cable should be lubricated or (all-purpose grease)
replaced if necessary.
NOTE:
@
Since the throttle grip must be removed

to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time.
@
1. Remove the throttle grip by remov- 6

ing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throt-
tle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.
6-24
EAU03370 EAU03164 EAU03165
Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals brake and clutch levers sidestand
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand should
6 pedals should be checked before each levers should be checked before each be checked before each ride, and the
ride, and the pedal pivots should be lu- ride, and the lever pivots should be lu- sidestand pivot and metal-to-metal
bricated if necessary. bricated if necessary. contact surfaces should be lubricated if
necessary.
Recommended lubricant: Recommended lubricant: EW000113
Lithium-soap-based grease Lithium-soap-based grease @

WARNING
(all-purpose grease) (all-purpose grease) If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
@
6-25

EAU00790
Recommended lubricant: Lubricating the rear

Lithium-soap-based grease suspension
(all-purpose grease)
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Molybdenum disulfide grease
6-26

EAU02939 EAU00794
Checking the front fork Checking the steering

The condition and operation of the front Worn or loose steering bearings may
fork must be checked as follows at the cause danger. Therefore, the operation
intervals specified in the periodic main- of the steering must be checked as fol-
tenance and lubrication chart. lows at the intervals specified in the pe-
riodic maintenance and lubrication
To check the condition chart.
EW000115
1. Place a stand under the engine to
@
WARNING raise the front wheel off the
Securely support the motorcycle so To check the operation ground.
that there is no danger of it falling 1. Place the motorcycle on a level
EW000115
over. surface and hold it in an upright @

WARNING
@
position. Securely support the motorcycle so

Check the inner tubes for scratches,
6 2. While applying the front brake, that there is no danger of it falling
damage and excessive oil leakage.
push down hard on the handle- over.
@
bars several times to check if the

front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:
@
If any damage is found or the front

fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
@
6-27

EAU01144
Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion 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.
2. Hold the lower ends of the front

fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the 6
steering.
6-28

3. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
EW000116
@
WARNING
● Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
1. Battery 1. Maximum level mark
2. Pass through the battery case. 2. Minimum level mark
burns. Avoid any contact with
3. Pass through the frame. skin, eyes or clothing and al-
4. Pass through the guide. To check the electrolyte level ways shield your eyes when
5. Pass through the engine bracket. 1. Place the motorcycle on a level working near batteries. In case
6. Battery breather hose surface and hold it in an upright of contact, administer the fol-
6 EAU00798 position. lowing FIRST AID.
Battery
NOTE: • EXTERNAL: Flush with plenty
A poorly maintained battery will cor- @
Make sure that the motorcycle is posi- of water.

rode and discharge quickly. The elec-
tioned straight up when checking the • INTERNAL: Drink large quan-
trolyte level, battery lead connections
electrolyte level. tities of water or milk and im-
and breather hose routing should be @
mediately call a physician.
checked before each ride and at the in- 2. Check the electrolyte level in the • EYES: Flush with water for
tervals specified in the periodic mainte- battery.
15 minutes and seek prompt
nance and lubrication chart.
NOTE: medical attention.
@
The electrolyte should be between the ● Batteries produce explosive hy-

minimum and maximum level marks. drogen gas. Therefore, keep
@
sparks, flames, cigarettes, etc.,
6-29

away from the battery and pro- 2. If the battery will be stored for
vide sufficient ventilation when more than two months, check the
charging it in an enclosed specific gravity of the electrolyte at
space. least once a month and fully
● KEEP THIS AND ALL BATTER- charge the battery whenever
IES OUT OF THE REACH OF necessary.
CHILDREN. 3. Fully charge the battery before
@
EC000100 installation.
CAUTION: 4. After installation, make sure that
@
the battery leads are properly con-

Use only distilled water, as tap water
nected to the battery terminals and
contains minerals that are harmful
that the breather hose is properly
to the battery.
@ routed, in good condition, and not
4. Check and, if necessary, tighten obstructed.
the battery lead connections and EC000099 6
correct the breather hose routing. CAUTION:
@
If the breather hose is positioned in

To store the battery such a way that the frame is ex-
1. If the motorcycle will not be used posed to electrolyte or gas expelled
for more than one month, remove from the battery, the frame could
the battery, fully charge it, and suffer structural and external
then place it in a cool, dry place. damages.
@
6-30

Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 15 A
EC000103
CAUTION:
@
1. Main fuse
Do not use a fuse of a higher amper- 1. Screw (× 2)
2. Headlight fuse age rating than recommended to
EAU03003
3. Signaling system fuse avoid causing extensive damage to
4. Ignition fuse
Replacing the headlight bulb
the electrical system and possibly a This motorcycle is equipped with a
5. Spare fuse (× 2)
fire. quartz bulb headlight. If the headlight
EAU00818 @
6 Replacing the fuses 3. Turn the key to “ON” and turn on bulb burns out, replace it as follows.
The fuse box is located under the rider the electrical circuit in question to 1. Remove the headlight unit by re-
seat. (See page 3-8 for rider seat re- check if the device operates. moving the screws.
moval and installation procedures.) 4. If the fuse immediately blows
If a fuse is blown, replace it as follows. again, have a Yamaha dealer
1. Turn the key to “OFF” and turn off check the electrical system.
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
6-31
1. Headlight coupler 1. Headlight bulb holder 1. Do not touch this area.

2. Headlight bulb cover
3. Remove the headlight bulb holder EC000105
2. Disconnect the headlight coupler, by turning it counterclockwise, and CAUTION:

@
and then remove the headlight unit then remove the defective bulb. Do not touch the glass part of the
and bulb cover. EW000119 headlight bulb to keep it free from
@
WARNING oil, otherwise the transparency of 6
Headlight bulbs get very hot. There- the glass, the luminosity of the bulb,
fore, keep flammable products away and the bulb life will be adversely af-
from a lit headlight bulb, and do not fected. Thoroughly clean off any dirt
touch the bulb until it has cooled and fingerprints on the headlight
down. bulb using a cloth moistened with
@
alcohol or thinner.
4. Place a new bulb into position, and @
then secure it with the bulb holder. 5. Install the bulb cover, and then
connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
6-32

EAU01579
Supporting the motorcycle

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
1. Screw (× 2) 1. Tail/brake light bulb (× 2) before starting any maintenance. A
strong wooden box can be placed un-
EAU00855
2. Remove the defective bulb by
Replacing a turn signal light der the engine for added stability.
pushing it in and turning it counter-
bulb or the tail/brake light clockwise.
To service the front wheel
bulb 3. Insert a new bulb into the socket, 1. Stabilize the rear of the motorcycle
6 1. Remove the lens by removing the push it in, and then turn it clock- by using a motorcycle stand or, if
screws. wise until it stops. an additional motorcycle stand is
4. Install the lens by installing the not available, by placing a jack un-
screws. der the frame in front of the rear
EC000108
wheel.
CAUTION: 2. Raise the front wheel off the
@
Do not overtighten the screws, oth- ground by using a motorcycle

erwise the lens may break. stand.
@
6-33

To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Speedometer cable 1. Front wheel axle pinch bolt

2. Wheel axle
EAU03239
Front wheel 2. Loosen the front wheel axle pinch

bolt, then the wheel axle.
To remove the front wheel 3. Lift the front wheel off the ground
EW000122
according to the procedure on 6
_
WARNING page 6-33.
● It is advisable to have a Yamaha 4. Pull the wheel axle out, and then
dealer service the wheel. remove the wheel.
● Securely support the motor- ECA00048
cycle so that there is no danger CAUTION:

_
of it falling over. Do not apply the brake after the

_
1. Disconnect the speedometer ca- wheel has been removed together

ble from the front wheel. with the brake disc, otherwise the
brake pads will be forced shut.
_
6-34

5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Tighten the wheel axle to the
specified torque.
Tightening torque:
Wheel axle:
58 Nm (5.8 m·kg)
1. Retainer 1. Axle nut cotter pin
2. Axle nut
EAU01394 7. Install the front wheel axle pinch
To install the front wheel bolt, and then tighten it to the EAU01337
1. Install the speedometer gear unit specified torque.

Rear wheel
into the wheel hub so that the pro-
6 jections mesh with the slots. To remove the rear wheel
Tightening torque: EW000122
2. Lift the wheel up between the fork Front wheel axle pinch bolt:
legs. WARNING
23 Nm (2.3 m·kg) _
● It is advisable to have a Yamaha

NOTE:
_
8. Connect the speedometer cable. dealer service the wheel.
Make sure that there is enough space ● Securely support the motor-
between the brake pads before insert- cycle so that there is no danger
ing the brake disc and that the slot in of it falling over.
the speedometer gear unit fits over the _
retainer on the fork leg. 1. Remove the axle nut cotter pin,
_
and then loosen the axle nut.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
6-35

6. Loosen the rear wheel axle pinch
bolt, and then pull the wheel axle
out.
7. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
1. Rear wheel axle pinch bolt

2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake torque rod bolt/nut/cotter pin
5. Brake torque rod
6. Wheel axle
2. Disconnect the brake torque rod 6

from the brake shoe plate by re-
moving the cotter pin, the nut, and
the bolt.
3. Lift the rear wheel off the ground
according to the procedure on
page 6-33.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove the axle nut.
6-36

6. Lower the rear wheel so that it is EAU01008
on the ground. Troubleshooting

7. Tighten the axle nut, pinch bolt Although Yamaha motorcycles receive
and brake torque rod nut to the a thorough inspection before shipment
specified torques. from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
Tightening torques: compression, or ignition systems, for
Axle nut: example, can cause poor starting and
107 Nm (10.7 m·kg) loss of power.
Rear wheel axle pinch bolt: The following troubleshooting chart
EAU01406 16 Nm (1.6 m·kg) represents a quick and easy procedure
To install the rear wheel Brake torque rod nut: for checking these vital systems your-
1. Apply a light coating of lithium- 20 Nm (2.0 m·kg) self. However, should your motorcycle
soap-based grease to the splines require any repair, take it to a Yamaha
of the final gear case and wheel 8. Install the brake torque rod cotter
6 dealer, whose skilled technicians have
hub. pin.
EW000124
the necessary tools, experience, and
2. Install the wheel by inserting the know-how to service the motorcycle
wheel axle. WARNING
_
properly.
3. Install the brake rod onto the brake Always use a new cotter pin.
_ Use only genuine Yamaha replace-
camshaft lever, and then install 9. Adjust the brake pedal free play. ment parts. Imitation parts may look
the brake pedal free play adjusting (See page 6-20 for brake pedal like Yamaha parts, but they are often
nut onto the brake rod. free play adjustment procedures.) inferior, have a shorter service life and
4. Connect the brake torque rod to EW000103
can lead to expensive repair bills.
the brake shoe plate by installing _
WARNING
the bolt and the nut. After adjusting the brake pedal free
5. Install the rear wheel axle pinch play, check the operation of the
bolt. brake light.
_
6-37

EAU01562
Troubleshooting chart
EW000125
@
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compressoin.
2. Compression
There is compression. Check the ignition.
Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
6
3. Ignition Wipe off with a dry cloth and correct the Open throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
4. Battery The engine turns over

The battery is good.
quickly.
Operate the electric starter. Have a Yamaha dealer
Check the electrolyte and battery check the vehicle.
The engine turns over
lead connections, and charge the
slowly.
battery if necessary.
6-38

MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1

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


7-
EAU03412
Care Before cleaning Cleaning

While the open design of a motorcycle 1. Cover the muffler outlets with plas- ECA00010
reveals the attractiveness of the tech- tic bags after the engine has CAUTION:
@
nology, it also makes it more vulnera- cooled down. ● Avoid using strong acidic wheel
ble. Rust and corrosion can develop 2. Make sure that all caps and covers cleaners, especially on spoked
even if high-quality components are as well as all electrical couplers wheels. If such products are
used. A rusty exhaust pipe may go un- and connectors, including the used on hard-to-remove dirt, do
noticed on a car, however, it detracts spark plug caps, are tightly in- not leave the cleaner on the af-
from the overall appearance of a stalled. fected area any longer than in-
motorcycle. Frequent and proper care 3. Remove extremely stubborn dirt, structed. Also, thoroughly rinse
does not only comply with the terms of like oil burnt onto the crankcase, the area off with water, immedi-
the warranty, but it will also keep your with a degreasing agent and a ately dry it, and then apply a
motorcycle looking good, extend its life brush, but never apply such prod- corrosion protection spray.
and optimize its performance. ucts onto seals, gaskets and ● Improper cleaning can damage
wheel axles. Always rinse the dirt windshields, cowlings, panels
and degreaser off with water. and other plastic parts. Use
7 only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
7-1

● Do not use any harsh chemical ● For motorcycles equipped with After riding in the rain, near the sea or
products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads
sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads
sponges which have been in they will cause dulling or during winter are extremely corrosive in
contact with strong or abrasive scratching. Some cleaning combination with water, carry out the
cleaning products, solvent or compounds for plastic may following steps after each ride in the
thinner, fuel (gasoline), rust re- leave scratches on the wind- rain, near the sea or on salt-sprayed
movers or inhibitors, brake flu- shield. Test the product on a roads.
id, antifreeze or electrolyte. small hidden part of the wind-
● Do not use high-pressure wash- shield to make sure that it does NOTE:
@
Salt sprayed on roads in the winter may

ers or steam-jet cleaners since not leave any marks. If the wind-
remain well into spring.
they cause water seepage and shield is scratched, use a quali- @
deterioration in the following ar- ty plastic polishing compound 1. Clean the motorcycle with cold
eas: seals (of wheel and swing- after washing. water and a mild detergent, after
arm bearings, fork and brakes), @
the engine has cooled down.
ECA00012
electric components (couplers,
After normal use CAUTION:
connectors, instruments, 7
Remove dirt with warm water, a mild @
switches and lights), breather Do not use warm water since it in-
detergent, and a soft, clean sponge,
hoses and vents. creases the corrosive action of the
and then rinse thoroughly with clean
salt.
water. Use a toothbrush or bottlebrush @
for hard-to-reach areas. Stubborn dirt 2. After drying the motorcycle, apply
and insects will come off more easily if a corrosion protection spray on all
the area is covered with a wet cloth for metal, including chrome- and nick-
a few minutes before cleaning. el-plated, surfaces to prevent
corrosion.
7-2

After cleaning EWA00031
NOTE:
@
1. Dry the motorcycle with a chamois @

WARNING Consult a Yamaha dealer for advice on
or an absorbing cloth. ● Make sure that there is no oil or what products to use.
wax on the brakes or tires.
@
2. Use a chrome polish to shine

chrome, aluminum and stainless- ● If necessary, clean the brake
steel parts, including the exhaust discs and brake linings with a
system. (Even the thermally in- regular brake disc cleaner or ac-
duced discoloring of stainless- etone, and wash the tires with
steel exhaust systems can be re- warm water and a mild deter-
moved through polishing.) gent. Before riding at higher
3. To prevent corrosion, it is recom- speeds, test the motorcycle’s
mended to apply a corrosion pro- braking performance and cor-
tection spray on all metal, nering behavior.
@
including chrome- and nickel-plat- ECA00013
ed, surfaces. CAUTION:

4. Use spray oil as a universal clean-
@
● Apply spray oil and wax spar-

7 er to remove any remaining dirt. ingly and make sure to wipe off
5. Touch up minor paint damage any excess.
caused by stones, etc. ● Never apply oil or wax to any
6. Wax all painted surfaces. rubber and plastic parts, but
7. Let the motorcycle dry completely treat them with a suitable care
before storing or covering it. product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
@
7-3

Storage Long-term a. Remove the spark plug caps and
Before storing your motorcycle for sev- spark plugs.
Short-term eral months: b. Pour a teaspoonful of engine oil
Always store your motorcycle in a cool, 1. Follow all the instructions in the into each spark plug bore.
dry place and, if necessary, protect it “Care” section of this chapter. c. Install the spark plug caps onto the
against dust with a porous cover. 2. For motorcycles equipped with a spark plugs, and then place the
ECA00014 fuel cock that has an “OFF” posi- spark plugs on the cylinder head
CAUTION: tion: Turn the fuel cock lever to so that the electrodes are ground-
@
● Storing the motorcycle in a “OFF”. ed. (This will limit sparking during
poorly ventilated room or cover- 3. Drain the carburetor float cham- the next step.)
ing it with a tarp, while it is still bers by loosening the drain bolts; d. Turn the engine over several times
wet, will allow water and humid- this will prevent fuel deposits from with the starter. (This will coat the
ity to seep in and cause rust. building up. Pour the drained fuel cylinder walls with oil.)
● To prevent corrosion, avoid into the fuel tank. e. Remove the spark plug caps from
damp cellars, stables (because 4. Fill up the fuel tank and add fuel the spark plugs, and then install
of the presence of ammonia) stabilizer (if available) to prevent the spark plugs and the spark plug
and areas where strong chemi- the fuel tank from rusting and the caps. 7
cals are stored. fuel from deteriorating. EWA00003
@
5. Perform the following steps to pro- @
WARNING
tect the cylinders, piston rings, etc. To prevent damage or injury from
from corrosion. sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
@
7-4

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. Alterna-
tively, 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 plas-
tic bags to prevent moisture from
entering them.
9. Remove the battery and fully
7 charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-30.
NOTE:
@
Make any necessary repairs before

storing the motorcycle.
@
7-5
SPECIFICATIONS
Specifications ..................................................................................... 8-1

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

SPECIFICATIONS
8-
EAU01038
Specifications
CS-01E
Model XV535 Engine oil
Dimensions Type
-20 -10 0 10 20 30 40 50 ˚C
Overall length 2,225 mm (except for N, S, SF)
SAE 10W–30
2,250 mm (for N, S, SF)
Overall width 780 mm SAE 10W–40
Overall height 1,120 mm SAE 15W–40

Seat hight 720 mm SAE 20W–40
Wheelbase 1,520 mm
SAE 20W–50
Ground clearance 160 mm
Minimum turning radius 2,900 mm Recommended engine oil
classification API Service SE, SF, SG type or
Basic weight (with oil and full higher
fuel tank) 195 kg (except for A)
197 kg (for A) CAUTION:
Engine Be sure to use motor oils that do not contain anti-friction

modifiers. Passenger car motor oils (often labeled
Engine type Air-cooled 4-stroke, SOHC “ENERGY CONSERVING II”) contain anti-friction additives
Cylinder arrangement V-type, 2-cylinder which will cause clutch and/or starter clutch slippage, result-
8 ing in reduced component life and poor engine performance.
Displacement 535 cm3
Bore × Stroke 76.0 × 59.0 mm
Quantity
Compression ratio 9:1
Without oil filter element
Starting system Electric starter replacement 2.6 L
Lubrication system Wet sump With oil filter element
replacement 2.8 L
Total amount (dry engine) 3.2 L
8-1
SPECIFICATIONS
Final gear oil Gear ratio
Type Hypoid gear oil SAE 80 1st 2.714
(API GL4) or multigrade hypoid 2nd 1.900
gear oil SAE 80W-90
3rd 1.458
Quantity 0.19 L
4th 1.167
Air filter Dry type element
5th 0.967
Fuel
Chassis
Type Regular unleaded gasoline
Frame type Pressed backbone
Fuel tank capacity 13.5 L
Caster angle 31.5°
Fuel reserve amount 2.5 L
Trail 125 mm
Carburetor
Tires
Manufacturer MIKUNI
Front
Model × quantity BDS34 × 2
Type Tube tire
Spark plug
Size 3.00-19 49S
Manufacturer/model NGK / BPR6ES or
DENSO / W20EPR-U Manufacturer/
model Bridgestone / L303A
Gap 0.7–0.8 mm
Dunlop / F14G
Clutch type Wet, multiple-disc
Rear
Transmission 8
Type Tube tire
Primary reduction system Spur gear
Size 140/90-15 M/C 70S
Primary reduction ratio 1.944
Manufacturer/
Secondary reduction system Shaft drive model Bridgestone / G508
Secondary reduction ratio 3.071 Dunlop / K425
Transmission type Constant mesh, 5-speed
Operation Left foot
8-2
SPECIFICATIONS
Maximum load* 220 kg (except for A) Rear
218 kg (for A) Type Drum brake
Tire air pressure Operation Right foot
(measured on cold tires)
Suspension
Up to 90 kg*
Front Telescopic fork
Front 200 kPa (2.00 kg/cm2, 2.00 bar) Rear Swingarm
Rear 225 kPa (2.25 kg/cm2, 2.25 bar)
Springs/shock absorbers
90 kg–maximum*
Front Coil spring / oil damper
Front 200 kPa (2.00 kg/cm2, 2.00 bar) Rear Coil spring / oil damper
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
Wheel travel
* Total weight of rider, passenger, cargo and accessories
Front 150 mm
Wheels Rear 85 mm
Front
Electrical system
Type Spoke wheel Ignition system T.C.I. (digital)
Size 19 × MT 1.85
Charging system
Rear
Type A.C. magneto
Type Spoke wheel Standard output 14 V, 24 A @ 5,000 r/min
8 Size 15 M/C × MT 3.00
Battery
Brakes
Model GM12AZ-3A-2
Front Voltage, capacity 12 V, 12 Ah
Type Single disc brake
Headlight type Quartz bulb (halogen)
Operation Right hand
Fluid DOT 4 or DOT 3
8-3
SPECIFICATIONS
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Auxiliary light 12 V, 4 W × 1 (except for GB)
12V, 3.4 W × 1 (for GB)
Tail/brake light 12 V, 5/21 W × 2
Front turn signal light 12 V, 21 W × 2
Rear turn signal light 12 V, 21 W × 2
Meter lighting 14 V, 3 W × 1
Neutral indicator light 14 V, 3 W × 1
High beam indicator light 12 V, 1.7 W × 1
Turn signal indicator light 14 V, 3 W × 1
Fuses
Main fuse 30 A
Ignition fuse 15 A
Signaling system fuse 15 A
Headlight fuse 15 A
8-4
SPECIFICATIONS
EAU01064
Conversion table
CS-02E
Conversion table
All specification data in this manual are listed in SI and METRIC TO IMPERIAL
METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb
m·kg 86.794 in·lb
unit data. Torque
cm·kg 0.0723 ft·lb
Example cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
METRIC MULTIPLIER IMPERIAL g 0.03527 oz
Speed km/h 0.6214 mi/h
** mm × 0.03937 = ** in
km 0.6214 mi
m 3.281 ft
2 mm × 0.03937 = 0.08 in Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume, cc (cm3) 0.06102 cu·in
Capacity L (liter) 0.8799 qt (IMP liq.)
L (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Miscellaneous kg/cm2 14.2234 psi (lb/in2)
8 Centigrade (°C) 9/5 + 32 Fahrenheit (°F)
8-5
CONSUMER INFORMATION
Identification numbers ........................................................................ 9-1

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

9-
EAU01039
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
1. Key identification number 1. Vehicle identification number
1. KEY IDENTIFICATION NUMBER: EAU01042 EAU01043
CA-02E Key identification number Vehicle identification number

The key identification number is The vehicle identification number is
stamped into the key. Record this num- stamped into the steering head pipe.
ber in the space provided and use it for Record this number in the space
2. VEHICLE IDENTIFICATION reference when ordering a new key. provided.
NUMBER:
CA-02E
NOTE:
@
The vehicle identification number is

used to identify your motorcycle and
may be used to register your motor-
9 cycle with the licensing authority in
3. MODEL LABEL INFORMATION: your area.
CA-01E @
9-1
1. Model label
EAU01804
Model label
The model label is affixed to the frame
under the rider seat. (See page 3-7 for
seat removal and installation proce-
dures.) Record the information on this
label in the space provided. This infor-
mation will be needed when ordering
spare parts from a Yamaha dealer.
9-2
INDEX
10-
A E L
Air filter element, cleaning ......................6-11 Engine break-in ....................................... 5-4 Light switch ..............................................3-3
Engine oil and oil filter element ................ 6-7
B M
Engine stop switch................................... 3-3
Battery ...................................................6-29 Main switch ..............................................3-1
Brake and clutch levers, checking and F Model label ..............................................9-2
lubricating ............................................6-25 Final gear oil............................................ 6-9
N
Brake and shift pedals, checking and Front fork, checking ............................... 6-27
Neutral indicator light ...............................3-1
lubricating ............................................6-25 Fuel ......................................................... 3-5
Brake fluid, changing .............................6-23 Fuel consumption, tips for reducing ......... 5-4 P
Brake fluid level, checking......................6-22 Fuel reserve switch.................................. 3-3 Parking.....................................................5-5
Brake lever...............................................3-4 Fuel tank cap........................................... 3-5 Part locations ...........................................2-1
Brake lever free play, adjusting ..............6-19 Fuses, replacing .................................... 6-31 Pass switch..............................................3-2
Brake light switch, adjusting ...................6-21 Periodic maintenance and lubrication
H
Brake pads and shoes, checking ...........6-21 chart ......................................................6-2
Handlebar switches ................................. 3-2
Brake pedal..............................................3-4 Pre-operation check list............................4-1
Headlight bulb, replacing ....................... 6-31
Brake pedal position and free play,
Helmet holder .......................................... 3-9 S
adjusting ..............................................6-19
High beam indicator light ......................... 3-1 Safety information ....................................1-1
C Horn switch ............................................. 3-2 Seats .......................................................3-7
Cables, checking and lubricating............6-23 Passenger seat...................................3-7
I
Carburetors, adjusting............................6-13 Rider seat ...........................................3-8
Identification numbers ............................. 9-1
Care.........................................................7-1 Shifting.....................................................5-3
Idling speed, adjusting ........................... 6-13
Clutch lever..............................................3-3 Shift pedal................................................3-4
Ignition circuit cut-off system.................. 3-10
Clutch lever free play, adjusting .............6-18 Shift points (for Switzerland only) .............5-3
Indicator lights ......................................... 3-1
Conversion table......................................8-5 Shock absorber assemblies, adjusting .....3-9
K Sidestand...............................................3-10
D
Key identification number ........................ 9-1 Sidestand, checking and lubricating .......6-25
Dimmer switch .........................................3-2

INDEX
Spark plugs, checking ............................. 6-5 W
Specifications .......................................... 8-1 Wheel bearings, checking ..................... 6-28
Speedometer unit .................................... 3-2 Wheel (front) ......................................... 6-34
Starter (choke) lever ................................ 3-6 Installing .......................................... 6-35
Starting a cold engine .............................. 5-1 Removing ........................................ 6-34
Starting a warm engine............................ 5-2 Wheel (rear) .......................................... 6-35
Start switch.............................................. 3-3 Installing .......................................... 6-37
Steering, checking ................................. 6-27 Removing ........................................ 6-35
Steering lock............................................ 3-7 Wheels.................................................. 6-17
Storage.................................................... 7-4
Supporting the motorcycle ..................... 6-33
Suspension (rear), lubricating ................ 6-26
T
Throttle cable free play, adjusting .......... 6-14
Throttle grip and cable, checking and
lubricating............................................ 6-24
Tires ...................................................... 6-15
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-37
Troubleshooting chart............................ 6-38
Turn signal indicator light ......................... 3-1
Turn signal or tail/brake light bulb,
replacing ............................................. 6-33
Turn signal switch.................................... 3-2
V
Valve clearance, adjusting..................... 6-14
Vehicle identification number ................... 9-1



YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2000 · 7 - 0.2 × 1 CR
(E)

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OWNER’S MANUAL

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Welcome to the Yamaha world of motorcycling!

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IMPORTANT MANUAL INFORMATION EAU00005

Particularly important information is distinguished in this manual by the following notations:

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

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IMPORTANT MANUAL INFORMATION

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IMPORTANT MANUAL INFORMATION

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1 GIVE SAFETY THE RIGHT OF WAY 1

3 INSTRUMENT AND CONTROL FUNCTIONS 3

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

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GIVE SAFETY THE RIGHT OF WAY

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

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GIVE SAFETY THE RIGHT OF WAY

Enjoy your ride!

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

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1. Headlight (page 6-31) 7. Shock absorber spring

1. Clutch lever (page 3-3)

INSTRUMENT AND CONTROL FUNCTIONS

Main switch ........................................................................................ 3-1

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INSTRUMENT AND CONTROL FUNCTIONS

The key can be removed. High beam indicator light “ ”

Do not use the parking position for Neutral indicator light “ ”

can be removed. EAU00057

Turn signal indicator light “ ”

INSTRUMENT AND CONTROL FUNCTIONS

Turn signal switch

Handlebar switches manually by pushing the switch in after

full tank of fuel. This information will en- EAU00129

able you to plan future fuel stops. Horn switch “ ”

INSTRUMENT AND CONTROL FUNCTIONS

See page 5-1 for starting instruc-

1. Engine stop switch EAU00149 1. Clutch lever

INSTRUMENT AND CONTROL FUNCTIONS

Shift pedal Brake lever Brake pedal

INSTRUMENT AND CONTROL FUNCTIONS

The fuel tank cap cannot be closed un-

Fuel tank cap EAU01183

the original position, and then re-

INSTRUMENT AND CONTROL FUNCTIONS

Immediately wipe off spilled fuel

If knocking (or pinging) occurs, use

INSTRUMENT AND CONTROL FUNCTIONS

Steering lock EAU02940

INSTRUMENT AND CONTROL FUNCTIONS

Make sure that the seats are properly

INSTRUMENT AND CONTROL FUNCTIONS