Professional Documents
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R6 5SL OWNER Manual
R6 5SL OWNER Manual
EAU26941
DECLARATION of CONFORMITY
We
Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Kazuji Kawai
INTRODUCTION
EAU10100
Failure to follow WARNING instructions could result in severe injury or death to the
WARNING motorcycle operator, a bystander, or a person inspecting or repairing the motor-
cycle.
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.
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM
EAU10200
YZF-R6
OWNER’S MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st edition, July 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1 Luggage strap holders ................. 3-24 Checking the throttle cable free
Sidestand ..................................... 3-24 play ........................................... 6-18
DESCRIPTION ..................................2-1 Ignition circuit cut-off system ........ 3-25 Valve clearance ........................... 6-19
Left view ..........................................2-1 Tires ............................................. 6-19
Right view ........................................2-2 PRE-OPERATION CHECKS ............. 4-1 Cast wheels ................................. 6-22
Controls and instruments.................2-3 Pre-operation check list .................. 4-2 Adjusting the clutch lever free
play ........................................... 6-22
INSTRUMENT AND CONTROL OPERATION AND IMPORTANT Adjusting the rear brake light
FUNCTIONS .......................................3-1 RIDING POINTS................................. 5-1 switch ....................................... 6-23
Immobilizer system .........................3-1 Starting the engine ......................... 5-1 Checking the front and rear
Main switch/steering lock ................3-2 Shifting ........................................... 5-2 brake pads ................................ 6-23
Indicator and warning lights ............3-3 Tips for reducing fuel Checking the brake fluid level ...... 6-24
Tachometer ....................................3-8 consumption ............................... 5-3 Changing the brake fluid .............. 6-25
Multi-function display ......................3-8 Engine break-in .............................. 5-3 Drive chain slack .......................... 6-25
Anti-theft alarm (optional) .............3-12 Parking ........................................... 5-4 Lubricating the drive chain ........... 6-27
Handlebar switches ......................3-12 Checking and lubricating the
Clutch lever ...................................3-14 PERIODIC MAINTENANCE AND cables ....................................... 6-27
Shift pedal .....................................3-14 MINOR REPAIR ................................. 6-1 Checking and lubricating the
Brake lever ...................................3-14 Owner’s tool kit ............................... 6-1 throttle grip and cable ............... 6-28
Brake pedal ..................................3-15 Periodic maintenance and Checking and lubricating the
Fuel tank cap ................................3-15 lubrication chart .......................... 6-2 brake and shift pedals .............. 6-28
Fuel ...............................................3-16 Removing and installing cowlings Checking and lubricating the
Fuel tank breather/overflow and panels .................................. 6-6 brake and clutch levers ............ 6-29
hose ..........................................3-17 Checking the spark plugs ............... 6-8 Checking and lubricating the
Catalytic converter ........................3-17 Engine oil and oil filter cartridge ..... 6-9 sidestand .................................. 6-29
Seats ............................................3-18 Coolant ......................................... 6-12 Lubricating the swingarm
Helmet holders .............................3-19 Checking the air filter element ...... 6-16 pivots ........................................ 6-30
Storage compartment ...................3-19 Air intake duct .............................. 6-17 Checking the front fork ................. 6-30
Adjusting the front fork ..................3-20 Adjusting the engine idling Checking the steering .................. 6-31
Adjusting the shock absorber speed ........................................ 6-18 Checking the wheel bearings ....... 6-31
assembly ...................................3-22 Battery ......................................... 6-32
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TABLE OF CONTENTS
Replacing the fuses ......................6-33
Replacing a headlight bulb ...........6-34
Tail/brake light ..............................6-35
Replacing a turn signal light
bulb ...........................................6-36
Replacing the license plate light
bulb ...........................................6-36
Replacing an auxiliary light bulb ...6-37
Supporting the motorcycle ............6-37
Front wheel ...................................6-38
Rear wheel ...................................6-40
Troubleshooting ............................6-42
Troubleshooting charts .................6-43
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
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SAFETY INFORMATION
EAU10281
AND/OR WHEN MADE NECES- • Ride where other motorists can
SARY BY MECHANICAL CONDI- see you. Avoid riding in another
MOTORCYCLES ARE SINGLE TIONS. motorist’s blind spot.
1 TRACK VEHICLES. THEIR SAFE USE ● Many accidents involve inexperi-
AND OPERATION ARE DEPENDENT Safe riding enced operators. In fact, many op-
UPON THE USE OF PROPER RIDING ● Always make pre-operation erators who have been involved in
TECHNIQUES AS WELL AS THE EX- checks. Careful checks may help accidents do not even have a cur-
PERTISE OF THE OPERATOR. EV- prevent an accident. rent motorcycle license.
ERY OPERATOR SHOULD KNOW ● This motorcycle is designed to car- • Make sure that you are qualified
THE FOLLOWING REQUIREMENTS ry the operator and a passenger. and that you only lend your
BEFORE RIDING THIS MOTOR- ● The failure of motorists to detect motorcycle to other qualified op-
CYCLE. and recognize motorcycles in traf- erators.
HE OR SHE SHOULD: fic is the predominating cause of • Know your skills and limits.
● OBTAIN THOROUGH INSTRUC- automobile/motorcycle accidents. Staying within your limits may
TIONS FROM A COMPETENT Many accidents have been caused help you to avoid an accident.
SOURCE ON ALL ASPECTS OF by an automobile driver who did • We recommend that you prac-
MOTORCYCLE OPERATION. not see the motorcycle. Making tice riding your motorcycle
● OBSERVE THE WARNINGS AND yourself conspicuous appears to where there is no traffic until you
MAINTENANCE REQUIRE- be very effective in reducing the have become thoroughly famil-
MENTS IN THE OWNER’S MAN- chance of this type of accident. iar with the motorcycle and all of
UAL. Therefore: its controls.
● OBTAIN QUALIFIED TRAINING • Wear a brightly colored jacket. ● Many accidents have been caused
IN SAFE AND PROPER RIDING • Use extra caution when you are by error of the motorcycle opera-
TECHNIQUES. approaching and passing tor. A typical error made by the op-
● OBTAIN PROFESSIONAL TECH- through intersections, since in- erator is veering wide on a turn
NICAL SERVICE AS INDICATED tersections are the most likely
BY THE OWNER’S MANUAL places for motorcycle accidents
to occur.
1-1
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SAFETY INFORMATION
due to EXCESSIVE SPEED or un- ● This motorcycle is designed for on- cause burns. Always wear protec-
dercornering (insufficient lean an- road use only. It is not suitable for tive clothing that covers your legs,
gle for the speed). off-road use. ankles, and feet.
• Always obey the speed limit and ● A passenger should also observe 1
never travel faster than warrant- Protective apparel the above precautions.
ed by road and traffic conditions. The majority of fatalities from motor-
• Always signal before turning or cycle accidents are the result of head Modifications
changing lanes. Make sure that injuries. The use of a safety helmet is Modifications made to this motorcycle
other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re-
● The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren-
passenger is important for proper ● Always wear an approved helmet. der the motorcycle unsafe for use and
control. ● Wear a face shield or goggles. may cause severe personal injury.
• The operator should keep both Wind in your unprotected eyes Modifications may also make your
hands on the handlebar and could contribute to an impairment motorcycle illegal to use.
both feet on the operator foot- of vision that could delay seeing a
rests during operation to main- hazard. Loading and accessories
tain control of the motorcycle. ● The use of a jacket, heavy boots, Adding accessories or cargo to your
• The passenger should always trousers, gloves, etc., is effective in motorcycle can adversely affect stabili-
hold onto the operator, the seat preventing or reducing abrasions ty and handling if the weight distribution
strap or grab bar, if equipped, or lacerations. of the motorcycle is changed. To avoid
with both hands and keep both ● Never wear loose-fitting clothes, the possibility of an accident, use ex-
feet on the passenger footrests. otherwise they could catch on the treme caution when adding cargo or
• Never carry a passenger unless control levers, footrests, or wheels accessories to your motorcycle. Use
he or she can firmly place both and cause injury or an accident. extra care when riding a motorcycle
feet on the passenger footrests. ● Never touch the engine or exhaust that has added cargo or accessories.
● Never ride under the influence of system during or after operation. Here are some general guidelines to
alcohol or other drugs. They become very hot and can follow if loading cargo or adding acces-
sories to your motorcycle:
1-2
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SAFETY INFORMATION
Loading bags, duffel bags, or tents, can limit suspension travel, steering
The total weight of the operator, pas- create unstable handling or a slow travel or control operation, or ob-
senger, accessories and cargo must steering response. scure lights or reflectors.
1 not exceed the maximum load limit. Accessories • Accessories fitted to the handle-
Genuine Yamaha accessories have bar or the front fork area can
Maximum load: been specifically designed for use on create instability due to improper
192 kg (423 lb) this motorcycle. Since Yamaha cannot weight distribution or aerody-
test all other accessories that may be namic changes. If accessories
When loading within this weight limit,
available, you must personally be re- are added to the handlebar or
keep the following in mind:
sponsible for the proper selection, in- front fork area, they must be as
● Cargo and accessory weight
stallation and use of non-Yamaha lightweight as possible and
should be kept as low and close to
accessories. Use extreme caution should be kept to a minimum.
the motorcycle as possible. Make
when selecting and installing any ac- • Bulky or large accessories may
sure to distribute the weight as
cessories. seriously affect the stability of
evenly as possible on both sides of
Keep the following guidelines in mind, the motorcycle due to aerody-
the motorcycle to minimize imbal-
as well as those provided under “Load- namic effects. Wind may at-
ance or instability.
ing” when mounting accessories. tempt to lift the motorcycle, or
● Shifting weights can create a sud-
● Never install accessories or carry the motorcycle may become un-
den imbalance. Make sure that ac-
cargo that would impair the perfor- stable in cross winds. These ac-
cessories and cargo are securely
mance of your motorcycle. Care- cessories may also cause
attached to the motorcycle before
fully inspect the accessory before instability when passing or being
riding. Check accessory mounts
using it to make sure that it does passed by large vehicles.
and cargo restraints frequently.
not in any way reduce ground • Certain accessories can dis-
● Never attach any large or heavy
clearance or cornering clearance, place the operator from his or
items to the handlebar, front fork,
her normal riding position. This
or front fender. These items, in-
improper position limits the free-
cluding such cargo as sleeping
dom of movement of the opera-
1-3
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SAFETY INFORMATION
tor and may limit control ability, ● Always turn the engine off before or clothing, immediately wash the
therefore, such accessories are leaving the motorcycle unattended affected area with soap and water
not recommended. and remove the key from the main and change your clothes.
● Use caution when adding electri- switch. When parking the motor- 1
cal accessories. If electrical acces- cycle, note the following:
sories exceed the capacity of the • The engine and exhaust system
motorcycle’s electrical system, an may be hot, therefore, park the
electric failure could result, which motorcycle in a place where pe-
could cause a dangerous loss of destrians or children are not like-
lights or engine power. ly to touch these hot areas.
• Do not park the motorcycle on a
Gasoline and exhaust gas slope or soft ground, otherwise it
● GASOLINE IS HIGHLY FLAMMA- may fall over.
BLE: • Do not park the motorcycle near
• Always turn the engine off when a flammable source, (e.g., a ker-
refueling. osene heater, or near an open
• Take care not to spill any gaso- flame), otherwise it could catch
line on the engine or exhaust fire.
system when refueling. ● When transporting the motorcycle
• Never refuel while smoking or in in another vehicle, make sure that
the vicinity of an open flame. it is kept upright. If the motorcycle
● Never start the engine or let it run should lean over, gasoline may
for any length of time in a closed leak out of the fuel tank.
area. The exhaust fumes are poi- ● If you should swallow any gaso-
sonous and may cause loss of line, inhale a lot of gasoline vapor,
consciousness and death within a or allow gasoline to get into your
short time. Always operate your eyes, see your doctor immediately.
motorcycle in an area that has ad- If any gasoline spills on your skin
equate ventilation.
1-4
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DESCRIPTION
EAU10410
Left view
1. Front fork rebound damping force adjusting screw (page 3-20) 10.Engine oil drain bolt (page 6-9)
2. Front fork spring preload adjusting bolt (page 3-20) 11.Engine oil filter cartridge (page 6-9)
3. Fuse box 2 (page 6-33) 12.Front fork compression damping force adjusting screw (page 3-20)
4. Coolant reservoir (page 6-12)
5. Shock absorber assembly spring preload adjusting ring (page 3-22)
6. Shock absorber assembly compression damping force adjusting screw
(page 3-22)
7. Owner’s tool kit (page 6-1)
8. Shock absorber assembly rebound damping force adjusting screw
(page 3-22)
9. Shift pedal (page 3-14)
2-1
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DESCRIPTION
EAU10420
Right view
2-2
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DESCRIPTION
EAU10430
2-3
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3-1
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3-2
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1. Push. CAUTION:
2. Turn. 1. Right turn signal indicator light “ ”
Do not use the parking position for 2. Fuel level warning light “ ”
Push the key in, and then turn it to an extended length of time, other- 3. Oil level warning light “ ”
“OFF” while still pushing it. wise the battery may discharge. 4. Neutral indicator light “ ”
EWA10060 5. Engine trouble warning light “ ”
WARNING 6. High beam indicator light “ ”
Never turn the key to “OFF” or 7. Immobilizer system indicator light “ ”
8. Left turn signal indicator light “ ”
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
3-3
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CAUTION:
Do not operate the engine if it is
overheated.
3-5
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Under 39 °C
Message “LO” is displayed. OK. Go ahead with riding.
(Under 103 °F)
3
40–116 °C
Temperature is displayed. OK. Go ahead with riding.
(104–241 °F)
Above 140 °C Message “HI” flashes. Stop the engine and allow it to cool.
(Above 284 °F) Warning light comes on. (See page 6-43.)
3-6
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3-7
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3-8
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3-9
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3-10
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1. Pass switch “ ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
5. Hazard switch “ ”
3-12
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3-13
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3-14
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knob with the “ ” mark on the brake Brake pedal Fuel tank cap
lever.
3-15
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WARNING EAU13390
3 Make sure that the fuel tank cap is
properly closed before riding.
Recommended fuel:
1. Fuel tank filler tube PREMIUM UNLEADED GASOLINE
ONLY
2. Fuel level
Fuel tank capacity:
Make sure that there is sufficient fuel in 17.0 L (4.49 US gal) (3.74 Imp.gal)
Fuel reserve amount (when the fuel
the tank. Fill the fuel tank to the bottom level warning light comes on):
of the filler tube as shown. 3.5 L (0.92 US gal) (0.77 Imp.gal)
EWA10880
WARNING ECA11400
brand. Use of unleaded fuel will extend Fuel tank breather/overflow Catalytic converter
spark plug life and reduce maintenance hose This vehicle is equipped with a catalytic
costs. converter in the muffler.
EWA10860
WARNING
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do- 3
ing any maintenance work.
ECA10700
CAUTION:
1. Fuel tank breather/overflow hose The following precautions must be
observed to prevent a fire hazard or
Before operating the motorcycle:
other damages.
● Check the fuel tank breather/over-
● Use only unleaded gasoline.
flow hose connection.
The use of leaded gasoline will
● Check the fuel tank breather/over-
cause unrepairable damage to
flow hose for cracks or damage,
the catalytic converter.
and replace it if damaged.
● Never park the vehicle near pos-
● Make sure that the end of the fuel
sible fire hazards such as grass
tank breather/overflow hose is not
or other materials that easily
blocked, and clean it if necessary.
burn.
● Make sure that the end of the fuel
● Do not allow the engine to idle
tank breather/overflow hose is po-
too long.
sitioned outside of the cowling.
3-17
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Passenger seat
1. Bolt
1. Projection
To install the rider seat 2. Seat holder
Insert the projection on the front of the
rider seat into the seat holder as 2. Remove the key.
shown, place the seat in the original po- NOTE:
sition, and then install the bolts. Make sure that the seats are properly
secured before riding.
1. Passenger seat lock
2. Unlock.
3-18
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load of 192 kg (423 lb) for the ve- compartment, be sure to wrap Adjusting the front fork
hicle. them in a plastic bag to prevent This front fork is equipped with spring
losing them. preload adjusting bolts, rebound damp-
ing force adjusting screws and com-
To place a U-LOCK in the storage pression damping force adjusting
compartment screws.
1. Remove the rubber cap from the EWA10180
1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw
3-21
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force and thereby soften the rebound pression damping force and thereby WARNING
damping, turn the adjusting screw in di- soften the compression damping, turn This shock absorber contains highly
rection (b). the adjusting screw in direction (b). pressurized nitrogen gas. For prop-
er handling, read and understand
Rebound damping setting: Compression damping setting: the following information before
Minimum (soft): Minimum (soft): handling the shock absorber. The
20 click(s) in direction (b)* 20 click(s) in direction (b)*
Standard: Standard: manufacturer cannot be held re-
sponsible for property damage or 3
6 click(s) in direction (b)* 5 click(s) in direction (b)*
Maximum (hard): Maximum (hard): personal injury that may result from
5 click(s) in direction (b)* 1 click(s) in direction (b)* improper handling.
* With the adjusting screw fully turned * With the adjusting screw fully turned ● Do not tamper with or attempt to
in direction (a) in direction (a)
open the gas cylinder.
● Do not subject the shock ab-
Compression damping force NOTE: sorber to an open flame or other
Although the total number of clicks of a high heat sources, otherwise it
damping force adjusting mechanism may explode due to excessive
may not exactly match the above spec- gas pressure.
ifications due to small differences in ● Do not deform or damage the
production, the actual number of clicks gas cylinder in any way, as this
always represents the entire adjusting will result in poor damping per-
range. To obtain a precise adjustment, formance.
it would be advisable to check the num- ● Always have a Yamaha dealer
ber of clicks of each damping force ad- service the shock absorber.
1. Compression damping force adjusting screw justing mechanism and to modify the
specifications as necessary.
To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting screw
3-23
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3-24
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WARNING
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.
3-25
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3-26
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PRE-OPERATION CHECKS
EAU15591
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.
NOTE:
Pre-operation checks should be made each time the vehicle 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.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
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PRE-OPERATION CHECKS
EAU15603
4-2
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PRE-OPERATION CHECKS
ITEM CHECKS PAGE
4-3
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● Never start the engine or oper- WARNING 2. Shift the transmission into the neu-
ate it in a closed area for any ● Before starting the engine, tral position.
5 length of time. Exhaust fumes check the function of the igni- NOTE:
are poisonous, and inhaling tion circuit cut-off system ac- When the transmission is in the neutral
them can cause loss of con- cording to the procedure position, the neutral indicator light
sciousness and death within a described on page 3-25. should be on, otherwise have a
short time. Always make sure ● Never ride with the sidestand Yamaha dealer check the electrical cir-
that there is adequate ventila- down. cuit.
tion.
1. Turn the key to “ON” and make 3. Start the engine by pushing the
● Before starting out, make sure
sure that the engine stop switch is start switch.
that the sidestand is up. If the
set to “ ”.
sidestand is not raised com- ECA11730 NOTE:
pletely, it could contact the CAUTION: If the engine fails to start, release the
ground and distract the opera- start switch, wait a few seconds, and
The following warning lights and in-
tor, resulting in a possible loss then try again. Each starting attempt
dicator light should come on for a
of control. should be as short as possible to pre-
few seconds, then go off.
● Oil level warning light
● Fuel level warning light
5-1
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5-2
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5-3
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Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING
● Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
● Do not park on a slope or on soft
ground, otherwise the vehicle 5
may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5-4
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6-1
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6-2
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6-3
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• Change.
22 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
Engine oil filter car-
23 • Replace. √ √ √
tridge
• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
24 * Cooling system
• Change. Every 3 years
Front and rear brake
25 * • Check operation. √ √ √ √ √ √
switches
Moving parts and ca-
26 • Lubricate. √ √ √ √ √
bles
• Check operation and free play.
Throttle grip housing
27 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
and cable
• Lubricate the throttle grip housing and cable.
6
• Check the air cut-off valve, reed valve, and hose for dam-
28 * Air induction system age. √ √ √ √ √
• Replace any damaged parts if necessary.
Muffler and exhaust
29 * • Check the screw clamp for looseness. √ √ √ √ √
pipe
Lights, signals and • Check operation.
30 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU18670
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.
6-4
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6-5
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EAU19012
Cowlings A and B
6-6
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1. Cowling A
2. Cowling B
6-8
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6-9
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6-10
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6-11
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WARNING
Never attempt to remove the radiator
1. Coolant reservoir cap cap when the engine is hot.
Coolant reservoir capacity (up to the 4. Install the reservoir cap, and then
maximum level mark): install the coolant reservoir cover
0.25 L (0.26 US qt) (0.22 Imp.qt) by installing the bolts.
6 ECA10470 NOTE:
CAUTION: ● The radiator fans are automatically 1. Clamp screw
switched on or off according to the 2. Air intake duct
● If coolant is not available, use
distilled water or soft tap water coolant temperature in the radia- 5. Remove the radiator cap.
instead. Do not use hard water tor. EWA10380
or salt water since it is harmful ● If the engine overheats, see page WARNING
to the engine. 6-43 for further instructions. Never attempt to remove the radiator
● If water has been used instead cap when the engine is hot.
of coolant, replace it with cool- EAU20343
1. Radiator cap
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CAUTION: breather hose and the fuel tank Air intake duct
● Make sure that the air filter ele- overflow hose in the original po-
ment is properly seated in the sition.
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
become excessively worn.
8. Install the air filter case cover by in-
1. Air intake duct
stalling the screws.
9. Place the fuel tank in the original Check that the screen of the intake duct
position, and then install the bolts. 1. Fuel tank breather hose is not blocked. Clean the screen if nec-
EWA11360
6 2. Fuel tank overflow hose essary.
WARNING
● Before placing the fuel tank in 10. Install the rider seat.
the original position, make sure
that the fuel hoses are not dam-
aged. If any fuel hose is dam-
aged, do not start the engine but
have a Yamaha dealer replace
the hose, otherwise fuel may
leak.
● Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
6-17
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Check the engine idling speed and, if The throttle cable free play should mea-
NOTE: sure 6.0–8.0 mm (0.24–0.31 in) at the
necessary, adjust it to specification by 6
If the specified idling speed cannot be throttle grip. Periodically check the
turning the idle adjusting screw. To in-
obtained as described above, have a throttle cable free play and, if neces-
crease the engine idling speed, turn the
Yamaha dealer make the adjustment. sary, have a Yamaha dealer adjust it.
screw in direction (a). To decrease the
engine idling speed, turn the screw in
direction (b).
6-18
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6-19
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NOTE:
The tire tread depth limits may differ
from country to country. Always comply 1. Tire air valve
with the local regulations. 2. Tire air valve core
3. Tire air valve cap with seal
6-20
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6-21
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1. Locknut
2. Clutch lever free play adjusting nut (crank-
case)
6-22
U5SLE2E0.book Page 23 Friday, August 6, 2004 9:48 AM
6. Install the cowling. Adjusting the rear brake light Checking the front and rear
switch brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22410
Front brake pads
6-23
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6-24
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ter the brake fluid reservoir when Changing the brake fluid Drive chain slack
refilling. Water will significantly Have a Yamaha dealer change the The drive chain slack should be
lower the boiling point of the fluid brake fluid at the intervals specified in checked before each ride and adjusted
and may result in vapor lock. the NOTE after the periodic mainte- if necessary.
● Brake fluid may deteriorate paint- nance and lubrication chart. In addition,
ed surfaces or plastic parts. Al- have the oil seals of the master cylin- EAU22770
To check the drive chain slack
ways clean up spilled fluid ders and calipers as well as the brake
1. Place the motorcycle on a level
immediately. hoses replaced at the intervals listed
surface and hold it in an upright po-
● As the brake pads wear, it is nor- below or whenever they are damaged
sition.
mal for the brake fluid level to grad- or leaking.
ually go down. However, if the ● Oil seals: Replace every two NOTE:
brake fluid level goes down sud- years. When checking and adjusting the drive
denly, have a Yamaha dealer ● Brake hoses: Replace every four chain slack, the motorcycle should be
check the cause. years. positioned straight up and there should
6 be no weight on it.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
6-25
U5SLE2E0.book Page 26 Friday, August 6, 2004 9:48 AM
EAU34310
To adjust the drive chain slack 6
1. Loosen the axle nut and the lock- 1. Axle nut
nut on each side of the swingarm. 2. Drive chain slack adjusting bolt
2. To tighten the drive chain, turn the 3. Locknut
adjusting bolt on each side of the 4. Alignment marks
swingarm in direction (a). To loos- ECA10570
6-27
U5SLE2E0.book Page 28 Friday, August 6, 2004 9:48 AM
Checking and lubricating the Checking and lubricating the Recommended lubricant:
Lithium-soap-based grease (all-pur-
throttle grip and cable brake and shift pedals pose grease)
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
6-28
U5SLE2E0.book Page 29 Friday, August 6, 2004 9:48 AM
Checking and lubricating the Recommended lubricant: Checking and lubricating the
Lithium-soap-based grease (all-pur-
brake and clutch levers pose grease) sidestand
Brake lever
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
6-29
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WARNING
Securely support the vehicle so that ECA10590
6-30
U5SLE2E0.book Page 31 Friday, August 6, 2004 9:48 AM
WARNING
Securely support the vehicle so that
there is no danger of it falling over.
6 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 steering.
6-31
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6-32
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6-33
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6-34
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CAUTION:
Take care not to damage the follow-
ing parts:
6 ● Headlight bulb
Do not touch the glass part of 1. Do not touch the glass part of the bulb.
the headlight bulb to keep it free
from oil, otherwise the transpar- 6. Connect the headlight coupler.
ency of the glass, the luminosity 7. Install the headlight bulb cover by
of the bulb, and the bulb life will turning it clockwise.
be adversely affected. Thor- 8. Install the panel.
oughly clean off any dirt and fin- 9. Have a Yamaha dealer adjust the
gerprints on the headlight bulb headlight beam if necessary.
using a cloth moistened with al-
cohol or thinner.
6-35
U5SLE2E0.book Page 36 Friday, August 6, 2004 9:48 AM
1. Screw 1. Screw
6
2. Remove the defective bulb by 2. Remove the socket (together with
pushing it in and turning it counter- the bulb) by pulling it out.
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA11190
CAUTION:
Do not overtighten the screw, other-
wise the lens may break. 1. License plate light bulb
2. License plate light unit
6-36
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6-37
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6-38
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NOTE:
1. Axle nut
● If the drive chain is difficult to re-
2. Drive chain slack adjusting bolt
move, remove the wheel axle first,
3. Locknut
4. Brake caliper
and then lift the wheel upward
5. Brake caliper bracket enough to remove the drive chain
from the rear sprocket.
6-40
U5SLE2E0.book Page 41 Friday, August 6, 2004 9:48 AM
6 1. Wheel axle
ECA11070
CAUTION: 1. Retainer
Do not apply the brake after the 2. Slot
wheel has been removed together 2. Install the drive chain onto the rear
with the brake disc, otherwise the sprocket.
brake pads will be forced shut. 3. Install the axle nut, and then lower
the rear wheel so that it is on the
EAU25661
ground.
To install the rear wheel
4. Adjust the drive chain slack. (See
1. Install the wheel and the brake cal-
page 6-25.)
iper bracket by inserting the wheel
5. Tighten the axle nut to the speci-
axle from the left-hand side.
fied torque.
6-41
U5SLE2E0.book Page 42 Friday, August 6, 2004 9:48 AM
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and 6
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
6-42
U5SLE2E0.book Page 43 Friday, August 6, 2004 9:48 AM
Troubleshooting charts
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 compression.
2. Compression
There is compression. Check the ignition.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
6-43
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WARNING
● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system. 6
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
6-44
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7-4
U5SLE2E0.book Page 1 Friday, August 6, 2004 9:48 AM
SPECIFICATIONS
Dimensions: Engine oil: Fuel:
Overall length: Type: Recommended fuel:
2045 mm (80.5 in) SAE10W30 or SAE10W40 or SAE15W40 Premium unleaded gasoline only
Overall width: or SAE20W40 or SAE20W50 Fuel tank capacity:
690 mm (27.2 in) 17.0 L (4.49 US gal) (3.74 Imp.gal)
Overall height: -20 -10 0 10 20 30 40 50 ˚C Fuel reserve amount:
1105 mm (43.5 in) 3.5 L (0.92 US gal) (0.77 Imp.gal)
SAE 10W-30
Seat height: Electronic fuel injection:
830 mm (32.7 in) SAE 10W-40 Manufacturer:
Wheelbase: NIPPON INJECTOR
1385 mm (54.5 in) SAE 15W-40 Model:
Ground clearance: INP-250/4
SAE 20W-40
145 mm (5.71 in) Spark plug(s):
Minimum turning radius: SAE 20W-50 Manufacturer/model:
3800 mm (149.6 in) NGK/CR9EK,CR10EK
Weight: Spark plug gap:
With oil and fuel: Recommended engine oil grade:
0.6–0.7 mm (0.024–0.028 in)
183.0 kg (403 lb) API service SE, SF, SG type or higher
Engine oil quantity:
Clutch:
Engine: Clutch type:
Without oil filter cartridge replacement:
Engine type: Wet, multiple-disc
2.40 L (2.54 US qt) (2.11 Imp.qt)
Liquid cooled 4-stroke, DOHC Transmission:
With oil filter cartridge replacement:
Cylinder arrangement: Primary reduction system:
2.60 L (2.75 US qt) (2.29 Imp.qt)
Forward-inclined parallel 4-cylinder Spur gear
Displacement:
Cooling system:
8 Coolant reservoir capacity (up to the
Primary reduction ratio:
600.0 cm³ (36.61 cu.in) 86/44 (1.955)
maximum level mark):
Bore × stroke: Secondary reduction system:
0.25 L (0.26 US qt) (0.22 Imp.qt)
65.5 × 44.5 mm (2.58 × 1.75 in) Chain drive
Radiator capacity (including all routes):
Compression ratio: Secondary reduction ratio:
2.15 L (2.27 US qt) (1.89 Imp.qt)
12.40 :1 48/16 (3.000)
Starting system: Air filter:
Transmission type:
Electric starter Air filter element:
Constant mesh 6-speed
Lubrication system: Wet element
Operation:
Wet sump Left foot operation
8-1
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM
SPECIFICATIONS
Gear ratio: Manufacturer/model: Rear wheel:
1st: MICHELIN/Pilot POWER Wheel type:
37/13 (2.846) Manufacturer/model: Cast wheel
2nd: DUNLOP/D218 M Rim size:
37/19 (1.947) Loading: 17M/C x MT5.50
3rd: Maximum load: Front brake:
28/18 (1.556) 192 kg (423 lb) Type:
4th: (Total weight of rider, passenger, cargo and Dual disc brake
32/24 (1.333) accessories) Operation:
5th: Tire air pressure (measured on cold Right hand operation
25/21 (1.190) tires): Recommended fluid:
6th: Loading condition: DOT 4
26/24 (1.083) 0–90 kg (0–198 lb) Rear brake:
Chassis: Front: Type:
Frame type: 250 kPa (36 psi) (2.50 kgf/cm²) Single disc brake
Diamond Rear: Operation:
Caster angle: 290 kPa (42 psi) (2.90 kgf/cm²) Right foot operation
24.50 ° Loading condition: Recommended fluid:
Trail: 90–192 kg (198–423 lb) DOT 4
95.0 mm (3.74 in) Front: Front suspension:
Front tire: 250 kPa (36 psi) (2.50 kgf/cm²) Type:
Type: Rear: Telescopic fork
Tubeless 290 kPa (42 psi) (2.90 kgf/cm²) Spring/shock absorber type:
Size: High-speed riding: Coil spring/oil damper 8
120/70 ZR17M/C (58W) Front: Wheel travel:
Manufacturer/model: 250 kPa (36 psi) (2.50 kgf/cm²) 120.0 mm (4.72 in)
MICHELIN/Pilot POWER C Rear: Rear suspension:
Manufacturer/model: 290 kPa (42 psi) (2.90 kgf/cm²) Type:
DUNLOP/D218F M Front wheel: Swingarm (link suspension)
Rear tire: Wheel type: Spring/shock absorber type:
Type: Cast wheel Coil spring/gas-oil damper
Tubeless Rim size: Wheel travel:
Size: 17M/C x MT3.50 120.0 mm (4.72 in)
180/55 ZR17M/C (73W)
8-2
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SPECIFICATIONS
Electrical system: Turn signal indicator light:
Ignition system: LED
DC. CDI Fuel level warning light:
Charging system: LED
AC magneto Coolant temperature warning light:
Battery: LED
Model: Engine trouble warning light:
GT9B-4 LED
Voltage, capacity: Immobilizer system indicator light:
12 V, 8.0 Ah LED
Headlight: Shift timing indicator light:
Bulb type: LED
Halogen bulb Fuses:
Bulb voltage, wattage x quantity: Main fuse:
Headlight: 40.0 A
12 V, 55.0 W × 2 Headlight fuse:
Tail/brake light: 20.0 A
LED Signaling system fuse:
Front turn signal light: 15.0 A
12 V, 10.0 W × 2 Ignition fuse:
Rear turn signal light: 15.0 A
12 V, 10.0 W × 2 Parking lighting fuse:
Auxiliary light: 10.0 A
8 12 V, 5.0 W × 2 Radiator fan fuse:
Licence plate light: 15.0 A × 2
12 V, 5.0 W × 1 Electronic fuel injection fuse:
Meter lighting: 15.0 A
LED Backup fuse:
Neutral indicator light: 10.0 A
LED
High beam indicator light:
LED
Oil level warning light:
LED
8-3
U5SLE2E0.book Page 1 Friday, August 6, 2004 9:48 AM
CONSUMER INFORMATION
EAU26351 EAU26381 EAU26400
9-1
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CONSUMER INFORMATION
EAU26470
Model label
1. Model label
9-2
U5SLE2E0.book Page 1 Friday, August 6, 2004 9:48 AM
INDEX
A Engine trouble warning light ....................3-7 N
Air filter element, checking ................... 6-16 F Neutral indicator light .............................. 3-4
Air intake duct ....................................... 6-17 Front and rear brake pads, checking ....6-23 O
Anti-theft alarm (optional) ..................... 3-12 Front fork, adjusting ..............................3-20 Oil level warning light .............................. 3-4
Auxiliary light bulb, replacing ................ 6-37 Front fork, checking...............................6-30 P
B Fuel .......................................................3-16 Parking.................................................... 5-4
Battery .................................................. 6-32 Fuel consumption, tips for reducing ........5-3 Part locations .......................................... 2-1
Brake and clutch levers, Fuel level warning light............................3-4 Pass switch........................................... 3-13
checking and lubricating..................... 6-29 Fuel tank breather/overflow hose..........3-17 Periodic maintenance and
Brake and shift pedals, Fuel tank cap.........................................3-15 lubrication chart .................................... 6-2
checking and lubricating..................... 6-28 Fuses, replacing....................................6-33 Pre-operation check list .......................... 4-2
Brake fluid, changing ............................ 6-25 H R
Brake fluid level, checking .................... 6-24 Handlebar switches ...............................3-12 Rear brake light switch, adjusting ......... 6-23
Brake lever ........................................... 3-14 Hazard switch........................................3-13 S
Brake pedal .......................................... 3-15 Headlight bulb, replacing.......................6-34 Safety information................................... 1-1
C Helmet holders ......................................3-19 Seats..................................................... 3-18
Cables, checking and lubricating.......... 6-27 High beam indicator light.........................3-4 Shifting.................................................... 5-2
Care........................................................ 7-1 Horn switch ...........................................3-13 Shift pedal............................................. 3-14
Catalytic converter................................ 3-17 I Shift timing indicator light ........................ 3-7
Clutch lever........................................... 3-14 Identification numbers .............................9-1 Shock absorber assembly, adjusting .... 3-22
Clutch lever free play, adjusting ........... 6-22 Ignition circuit cut-off system .................3-25 Sidestand.............................................. 3-24
Coolant ................................................. 6-12 Immobilizer system .................................3-1 Sidestand, checking and lubricating ..... 6-29
Coolant temperature warning light.......... 3-5 Immobilizer system indicator light ...........3-7 Spark plugs, checking............................. 6-8
Cowlings and panels, Indicator and warning lights ....................3-3 Specifications.......................................... 8-1
removing and installing......................... 6-6 K Starting the engine.................................. 5-1
D Key identification number........................9-1 Start switch ........................................... 3-13
Dimmer switch ...................................... 3-13 L Steering, checking ................................ 6-31
Drive chain, lubricating ......................... 6-27 License plate light bulb, replacing .........6-36 Storage ................................................... 7-3
Drive chain slack .................................. 6-25 Luggage strap holders ..........................3-24 Storage compartment ........................... 3-19
E M Supporting the motorcycle .................... 6-37
Engine break-in ...................................... 5-3 Main switch/steering lock ........................3-2 Swingarm pivots, lubricating ................. 6-30
Engine idling speed .............................. 6-18 Model label..............................................9-2 T
Engine oil and oil filter cartridge ............. 6-9 Multi-function display...............................3-8 Tachometer............................................. 3-8
Engine stop switch................................ 3-13 Tail/brake light ...................................... 6-35
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM
INDEX
Throttle cable free play, checking ......... 6-18
Throttle grip and cable,
checking and lubricating ..................... 6-28
Tires ...................................................... 6-19
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-42
Troubleshooting charts ......................... 6-43
Turn signal indicator lights ...................... 3-4
Turn signal light bulb, replacing ............ 6-36
Turn signal switch ................................. 3-13
V
Valve clearance .................................... 6-19
Vehicle identification number .................. 9-1
W
Wheel bearings, checking..................... 6-31
Wheel (front) ......................................... 6-38
Wheel (rear) .......................................... 6-40
Wheels .................................................. 6-22
U5SLE2E0.book Page 3 Friday, August 6, 2004 9:48 AM
OWNER’S MANUAL