PERIODIC MAINTENANCE AND MINOR REPAIR
EAUOl790 EAU00467
Safety is an obligation of the owner. PERIODIC MAINTENANCE
Periodic inspection, adjustment and lu- PROPER PERIODIC MAINTENANCE
brication will keep your vehicle in the OF YOUR MOTORCYCLE IS IMPOR-
safest and most efficient condition pos- TANT IN ORDER TO ENJOY LONG,
sible. The most important points of PLEASURABLE SERVICE. ESPE-
motorcycle inspection, adjustment, and CIALLY IMPORTANT ARE THE
lubrication are explained on the follow- MAINTENANCE SERVICES RELAT-
ing pages. ED TO EMISSIONS CONTROL.
Maintenance, replacement, or repair THESE CONTROLS NOT ONLY 1. Owner’s tool kit
of the emission control devices and FUNCTION TO ENSURE CLEANER 2. Rider seat backrest
systems may be performed by any AIR, BUT ARE ALSO VITAL TO EAU01659
repair establishment or individual PROPER ENGINE OPERATION AND Owner’s tool kit
that is certified (if applicable). MAXIMUM PERFORMANCE. IN THE The tool kit is located inside the storage
FOLLOWING PERIODIC MAINTE- compartment behind the rider seat
NANCE CHARTS, THE SERVICES backrest. (See page 3-9 for an expla-
If you are not familiar with motor- RELATED TO EMISSIONS CON- nation on moving the rider seat back-
cycle maintenance work, have a TROL ARE GROUPED SEPARATE- rest forward and back.)
Yamaha dealer do it for you. LY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEAL-
ERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000063
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes.
I
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
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Periodic maintenance chart for emission control system
-
INITIAL ODOMETER READINGS
600 mi 4,000 mi 8,066 mi 12,000 mi 16,000 mi 20,600 mi
rl0. ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
l Check and adjust valve clearance
I * Valve clearance Every 30,000 mi (42,000 km) or 42 months
when engine is cold.
l Check condition.
l Adjust gap and clean.
2 Spark plugs l Replace every 8,000 mi (13,000 km) 4 Replace. 4 Replace. 4
or 12 months and thereafter every
8,000 mi (13,000 km) or 12 months.
l Check ventilation hose for cracks or
Crankcase d d 4 4 4
3 * damage.
ventilation system l Replace if necessary.
l Check fuel hoses for cracks or
4 * Fuel line damage. -\i 4 d 4 4
l Replace if necessary.
l Replace initial 20,000 mi (31,000 km)
5 * Fuel filter or 30 months and thereafter every Replace.
20,000 mi (31,000 km) or 30 months.
l Check for leakage.
6 * Exhaust system l Retighten if necessary. -\i 4 d -\i 4
l Replace gasket(s) if necessary.
Carburetor 4 -\i 4 d 4 4
7 * l Adjust synchronization of carburetors.
synchronization
l Check and adjust engine idle speed.
8 l Idle speed l Adjust cable free play.
6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1 INITIAL 1 ODOMETER READINGS I
600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
No. ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
Evaporative
9 * emission control l Check control system for damage.
4 4
system (For l Replace if necessary.
California only)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-4
EAUOO472
General maintenance and lubrication chart
INITIAL ODOMETER READINGS
600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
No. ITEM ROUTINE TYPE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
l Replace (warm up
1 Engine oil engine before See page 8-l. 4 4 4 4 4 4
draining).
2 Oil filter l Replace. - 4 4 4
l Clean with
3 l Air filter compressed air. - 4 4 4 4 ‘4
l Replace if necessary.
l Check hose for cracks
or damage. - 4 4 4 4 4
4 l Cooling system l Replace if necessary.
l Replace coolant every Ethylene glycol Replace.
24 months. antifreeze coolant
l Adjust free play.
5 * Brake system l Replace pads if - li 4 4 4 4 4
necessary.
l Check operation and
fluid leakage. (See
6 * Clutch - 4 -\i 4 4 4 d
NOTE page 6-7.)
l Correct if necessary.
l Check oil level and
leakage.
SAE 80 API “GL-4”
7 Final gear oil l Replace every hypoid gear oil Replace. d 4 4 Replace. 4
16,000 mi (25,000 km)
or 24 months.
Yamaha chain and cable
8 Control and meter l Apply chain lube
lube or SAE 10w-30 4 4 4 d 4 d
cable thoroughly.
motor oil
6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL ODOMETER READINGS
600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
No. ITEM ROUTINE TYPE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
l Check bearing
assembly for
Swingarm pivot looseness. Lithium-soap-based Repack.
1 l -\i
bearing l Moderately repack grease
every 16,000 mi
(25,000 km).
l Apply lithium-soap-
Lithium-soap-based
Brake/clutch lever based grease
0 pivot shaft (all-purpose grease) (all-purpose grease) 4 4 4 4 4
lightly.
l Lubricate.
l Apply lithium-soap- Lithium-soap-based
1 Brake pedal and shift based grease grease 4 4 4 4 4
pedal shaft
(all-purpose grease) (all-purpose grease)
lightly.
l Check operation and
lubricate.
2 l Center/sidestand l Apply lithium-soap- Lithium-soap-based
pivots grease 4 4 4 4 4
based grease
(all-purpose grease) (all-purpose grease)
lightly.
l Check operation and
3 l Front fork leakage. - 4 4 4 4 4
l Check bearing
assembly for
looseness. Lithium-soap-based
4 l Steering bearings 4 4 4 Repack. 4
l Moderately repack grease
every 16,000 mi
(25,000 km).
l Check bearings for
5 l Wheel bearings smooth rotation. - 4 4 li 4 4
l Check specific gravity
6 l Battery and breather pipe for - 4 4 4 4 4
proper operation.
6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL ODOMETER READINGS
600 mi 4,000 mi 6,000 mi 12,000 mi 16,000 mi 20,000 mi
No. ITEM ROUTINE TYPE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 2 4 m o n t h s 30 months
l Check and clean or - li
17 l Sidestand switch 4 4 li li 4
replace if necessary.
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU01695
NOTE:
For odometer readings or time periods higher than 20,000 mi (31,000 km) or 30 months, follow the maintenance require-
ments listed in the maintenance chart under the 4,000 mi (7,000 km) or 6 month interval.
EAU03056
NOTE:
l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l Hydraulic brake and clutch systems
l After disassembling the master cylinder, caliper cylinder or clutch release cylinder, always replace the brake fluid.
Check the brake fluid level of the master cylinder and clutch release cylinder regularly and fill as required.
l Replace the oil seals on the inner parts of the master cylinder, caliper cylinder and clutch release cylinder every two
years.
l Replace the brake and clutch hoses every four years or if cracked or damaged.
6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
I.Cowling A 1. Unlock. 1. Holder (x 2)
2. Panel A 2. Projection (x 2)
EAU03415
3. Panel B Cowling A To install the cowling
To remove the cowling 1. Align the holders under the cowl-
Removing and installing 1. Insert the key into the lock, and ing with the projections on the
cowlings and panels then turn it clockwise. frame.
The cowlings and panels shown above 2. Pull the cowling off as shown. 2 . Push down on the rear of the cowl-
need to be removed to perform some ing until it locks in place.
of the maintenance jobs described in 3. Remove the key from the lock.
this chapter. Refer to this section each
time a cowling or panel needs to be re-
moved and installed.
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (x 2) 1. Screw (x 2) 1. Spark plug cap
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Panel A Panel B Checking the spark plugs
To remove the panel To remove the panel The spark plugs are important engine
1. Remove cowling A. (See page 6-8 Remove the screws, and then take the components, which are easy to check.
for cowling removal and installa- panel off. Since heat and deposits will cause any
tion procedures.) To install the panel spark plug to slowly erode, the spark
2 . Remove the screws, and then take Place the panel in the original position, plugs should be removed and checked
the panel off. and then install the screws. in accordance with the periodic mainte-
To install the panel nance and lubrication chart. In addition,
1. Place the panel in the original po- the condition of the spark plugs can re-
sition, and then install the screws. veal the condition of the engine.
2. Install the cowling.
To remove a spark plug
1. Remove the spark plug cap.
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
@J
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
3. Check each spark plug for elec-
trode erosion and excessive car-
1. Spark plug wrench bon or other deposits, and replace ‘-, Spark plug gap
it if necessary.
2. Remove the spark plug as shown, To install a spark plug
with the spark plug wrench includ- 1 . Measure the spark plug gap with a
Specified spark plug:
ed in the owner’s tool kit. wire thickness gauge and, if nec-
DPR8EA-9/NGK or
essary, adjust the gap to specifica-
X24EPR-U9/DENSO
To check the spark plugs tion.
1. Check that the porcelain insulator
around the center electrode on Spark plug gap:
each spark plug is a medium-to- 0.8-0.9 mm (0.03-0.04 in)
light tan (the ideal color when the
motorcycle is ridden normally). 2. Clean the surface of the spark
2 . Check that all spark plugs installed plug gasket and its mating sur-
in the engine have the same color. 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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To carburetor Engine oil and oil filter
+
cartridge
The engine oil level should be checked
before each ride. In addition, the oil
NOTE: must be changed and the oil filter car-
If a torque wrench is not available when
tridge replaced at the intervals speci-
installing a spark plug, a good estimate fied in the periodic maintenance and
of the correct torque is l/4-1/2 turn Canister lubrication chart.
past finger tight. However, the spark
plug should be tightened to the speci- To check the engine oil level
fied torque as soon as possible.
1. Place the motorcycle on the cen-
4. Install the spark plug cap. terstand.
NOTE:
EAU01796 Make sure that the motorcycle is posi-
Canister (for California only) tioned straight up when checking the oil
This model is equipped with a canister level. A slight tilt to the side can result in
to prevent the discharging of fuel vapor a false reading.
into the atmosphere.
2. Start the engine, warm it up for
l Check each hose connection.
several minutes, and then turn it
l Check each hose and canister for
off.
cracks or damage. Replace if
damaged.
l Make sure the vent hose is not
blocked. Clean it if necessary.
6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
I. Engine oil level check window 1. Engine oil filler cap 1. Engine oil drain bolt
2. Maximum level mark
3. Minimum level mark To change the engine oil (with or 3. Remove the engine oil filler cap
without oil filter cartridge replace- and drain bolt to drain the oil from
3 . Wait a few minutes until the oil set- the crankcase.
ment)
tles, and then check the oil level
1. Start the engine, warm it up for
through the check window located NOTE:
several minutes, and then turn it
at the bottom-right side of the Skip steps 4-6 if the oil filter cartridge is
off.
crankcase. not being replaced.
2. Place an oil pan under the engine
NOTE: to collect the used oil.
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
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