OWNER’S MANUAL XVS1100 5EL-28199-E1
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E_5el_Intro0.fm Page 1 Monday, May 1, 2000 9:26 AM INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a XVS1100, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the 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 your XVS 1100’s advantages.
E_5el_Info0.fm Page 1 Monday, May 1, 2000 9:35 AM IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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.
E_5el_Info0.fm Page 2 Monday, May 1, 2000 9:35 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_5el_Info0.fm Page 3 Monday, May 1, 2000 9:35 AM IMPORTANT MANUAL INFORMATION EAU00008 XVS1100 OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, June 1999 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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E_5el_LabelTOC.fm Page 1 Monday, May 1, 2000 9:36 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY.................................................
E_5el_Label.fm Page 1 Monday, May 1, 2000 9:36 AM give safety the right of way EAU00021 1- 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 your motorcycle’s value and operating condition.
E_5el_DescriptionTOC.fm Page 1 Monday, May 1, 2000 9:36 AM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls/Instruments ..........................................................................
E_5el_Description.fm Page 1 Monday, May 1, 2000 9:37 AM DESCRIPTION EAU00026 2- Left view 2 1. Shift pedal 2. Fuel cock 3. Rear shock absorber spring preload adjusting ring 4. Helmet holder 5. Storage compartment 6. Tool kit 7.
E_5el_Description.fm Page 2 Monday, May 1, 2000 9:37 AM DESCRIPTION Right view 2 8. Oil filter 9. Battery 10. Main fuse 11. Main switch/Steering lock 12. Air filter 13.
E_5el_Description.fm Page 3 Monday, May 1, 2000 9:37 AM DESCRIPTION Controls/Instruments 2 1. Clutch lever 2. Left handlebar switches 3. Starter (choke) “ ” 4. Speedometer 5. Fuel tank cap 6. Right handlebar switches 7. Throttle grip 8.
E_5el_FunctionsTOC.fm Page 1 Monday, May 1, 2000 9:37 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch/Steering lock................................................................... 3-1 Indicator lights .................................................................................... 3-2 Speedometer...................................................................................... 3-3 Antitheft alarm (optional) ....................................................................
E_5el_Functions.fm Page 1 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 Main switch/Steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00040 LOCK The steering is locked in this position and all electrical circuits are switched off. The key can be removed in this position.
E_5el_Functions.fm Page 2 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01590 (Parking) The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to “ ”. Do not use this position for an extended length of time as the battery may discharge.
E_5el_Functions.fm Page 3 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01672* 3 4. Engine trouble indicator light “ ” This indicator light will come on or flash if trouble occurs in a monitoring circuit. In such a case, take the motorcycle to a Yamaha dealer to have the self-diagnostic systems checked. To check that the engine trouble indicator light is working properly: Turn the main switch to “ON”.
E_5el_Functions.fm Page 4 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 EAU00127 Antitheft alarm (optional) 4. Turn signal switch To signal a right-hand turn, push the switch to “ ”. To signal a left-hand turn, push the switch to “ ”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. An antitheft alarm can be equipped to this motorcycle.
E_5el_Functions.fm Page 5 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00143 3. Start switch “ ” The starter motor cranks the engine when pushing the start switch. EC000005 CAUTION: See starting instructions prior to starting the engine. @ 3 @ 1. Engine stop switch 2. Lights switch 3. Start switch “ ” EAU00152 Clutch lever EAU00138 The clutch lever is located on the left handlebar, and the ignition circuit cutoff system is incorporated in the clutch lever holder.
E_5el_Functions.fm Page 6 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Shift pedal 1. Rear brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Front brake lever Rear brake pedal This motorcycle is equipped with a constant-mesh 5-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.
E_5el_Functions.fm Page 7 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. @ @ EW000023 WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle. @ 3 EAU02917 Fuel tank cap 1. Filler tube 2. Fuel level EAU01183 @ Fuel To remove Slide the lock cover open, insert the key and turn it 1/4 turn clockwise.
E_5el_Functions.fm Page 8 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. Off position Normal position @ @ EAU00191 3 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 17 L Reserve: 4.
E_5el_Functions.fm Page 9 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS ECA00038 Reserve position CAUTION: Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. Also, longer use of the starter (choke) will cause afterburning. If afterburning occurs, turn off the starter (choke). @ 3 1. Pointed end positioned over “RES” RES This indicates reserve. If you run out of fuel while riding, set the fuel cock to this position.
E_5el_Functions.fm Page 10 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Nut EAU01710 Seats Passenger seat To remove Remove the nut and pull the seat upward. 1. Projection 2. Seat holder 1. Bolt (× 2) 2. Bracket To install Insert the projection on the front of the seat into the seat holder and install the nut. Rider seat To remove Remove the passenger seat. Then, remove the bolts and bracket and pull the seat upward.
E_5el_Functions.fm Page 11 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Projection (× 2) 2. Seat holder (× 2) 1. Helmet holder To install 1. Insert the projections on the front of the rider seat into the seat holders, then place the seat in the original position. 2. Install the bracket and the bracket bolts. 3. Install the passenger seat. Helmet holder NOTE: Make sure that the seats are securely fitted.
E_5el_Functions.fm Page 12 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS 3 To open Slide the lock cover open, insert the key in the lock and turn it clockwise. 1. Storage compartment 1. Storage compartment Then, pull the storage compartment cover out as shown. To close Place the storage compartment cover in its original position as shown. Then, turn the key counterclockwise and remove it. Close the lock cover.
E_5el_Functions.fm Page 13 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01713 Rear shock absorber adjustment 3 This shock absorber is located under the rider seat. This shock absorber is equipped with a spring preload adjusting ring. Adjust spring preload as follows. 1. Remove the rider seat. (See page 3-10 for removal and installation procedures.) 1. Quick fastener (× 3) 2. Remove each quick fastener by pushing the center in with a screwdriver, then pulling the fastener out.
E_5el_Functions.fm Page 14 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS After removal Before installation 3 1. Quick fastener (× 3) 2. Mud guard 4. Remove the mud guard by removing each quick fastener. 1. Adjusting ring 2. Position indicator 3. Special wrench @ 5. Turn the adjusting ring in direction a to increase spring preload and in direction b to decrease spring preload. 6.
E_5el_Functions.fm Page 15 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00315 WARNING This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the cylinder assembly.
E_5el_Functions.fm Page 16 Monday, May 1, 2000 9:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00331 Sidestand/clutch switch operation check ENGINE WILL STALL. Check the operation of the sidestand switch and clutch switch against the information below. SIDESTAND SWITCH IS OK. CD-11E TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”. EW000045 WARNING If improper operation is noted, consult a Yamaha dealer immediately. @ @ TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.
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E_5el_PreopTOC.fm Page 1 Monday, May 1, 2000 9:39 AM PRE-OPERATION CHECKS Pre-operation check list......................................................................
E_5el_Preop.fm Page 1 Monday, May 1, 2000 9:39 AM PRE-OPERATION CHECKS EAU01114 4- Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
E_5el_Preop.fm Page 2 Monday, May 1, 2000 9:39 AM PRE-OPERATION CHECKS ITEM CHECKS Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. Lights, signals and switches • Check for proper operation. PAGE — 3-7 ~ 3-8 6-27 ~ 6-28 NOTE: Pre-operation checks should be made each time the motorcycle is used.
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E_5el_OperationTOC.fm Page 1 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS Starting the engine............................................................................. 5-1 Starting a warm engine ...................................................................... 5-4 Shifting ............................................................................................... 5-5 Recommended shift points (for Switzerland only) ..............................
E_5el_Operation.fm Page 1 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS 5- EAU00373 @ WARNING Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time.
E_5el_Operation.fm Page 2 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS CF-33E TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”. IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. 5 RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
E_5el_Operation.fm Page 3 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS ECA00023 CAUTION: The oil level indicator light should come on for 2 to 3 seconds when the main switch is turned to “ON” and then should go off. If the indicator light flickers or remains on, immediately stop the engine and check the engine oil level and for oil leakage. If necessary, fill the engine with oil and check to see that the oil level indicator light goes off.
E_5el_Operation.fm Page 4 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS 6. After starting the engine, move the starter (choke) halfway back. NOTE: For maximum engine life, never accelerate hard with a cold engine! @ EAU01258 Starting a warm engine The starter (choke) is not required when the engine is warm. EC000046 CAUTION: See the “Engine break-in” section prior to operating the motorcycle for the first time. @ @ 7.
E_5el_Operation.fm Page 5 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS EC000048 @ EAU00423 Shifting 5 The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly.
E_5el_Operation.fm Page 6 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: ● Warm up the engine before riding. ● Turn off the starter (choke) as soon as possible. ● Shift up swiftly and avoid high engine speeds during acceleration.
E_5el_Operation.fm Page 7 Monday, May 1, 2000 9:43 AM OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine. EW000058 WARNING The exhaust system is hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn.
E_5el_PeriodicTOC.fm Page 1 Monday, May 1, 2000 9:43 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit...................................................................6-1 Periodic maintenance and lubrication...................6-2 Panel removal and installation ..............................6-5 Panel A .................................................................6-5 Spark plugs...........................................................6-6 Engine oil ....................................................
E_5el_Periodic.fm Page 1 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
E_5el_Periodic.fm Page 2 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E EVERY NO. ITEM CHECKS AND MAINTENANCE JOBS 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Check condition. • Replace if necessary. 3 4 Spark plugs * Valves 5 INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) √ √ √ • Check condition.
E_5el_Periodic.fm Page 3 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 12,000 km or 12 months (whichever comes first) * Wheel bearings • Check bearing for looseness or damage. • Replace if necessary. √ √ * Swingarm • Check swingarm pivoting point for play. • Correct if necessary. • Lubricate with molybdenum disulfide grease every 24,000 km or 24 months (whichever comes first).
E_5el_Periodic.fm Page 4 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. 22 ITEM Final gear oil CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) • Check oil level and vehicle for oil leakage. • Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).
E_5el_Periodic.fm Page 5 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Bolt EAU01777 6 EAU00491 Panel removal and installation Panel A The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. To remove Remove the bolt and pull outward on the areas shown. 6-5 To install Place the panel in its original position and install the bolt.
E_5el_Periodic.fm Page 6 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 1. Cylinder head cover 1. Spark plug wrench EAU01673 Spark plugs Removal 1.
E_5el_Periodic.fm Page 7 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. @ @ a. Spark plug gap 6 4. Install the spark plug caps and the cylinder head covers. Installation 1.
E_5el_Periodic.fm Page 8 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Fill the engine with sufficient recommended oil. Install the oil filler cap and tighten it. 1. Engine oil filler cap 2. With the engine stopped, check the oil level through the level window located at the lower part of the left side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. @ @ 3. The oil level should be between the maximum and minimum marks.
E_5el_Periodic.fm Page 9 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Start the engine and warm it up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. NOTE: After the engine is started, the oil level indicator light should go off if oil is filled to the specified level.
E_5el_Periodic.fm Page 10 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR Final gear case capacity: 0.2 L Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: “GL-4” is a quality and additive rating. Hypoid gear oils rated “GL-5” or “GL-6” may also be used. @ @ 5. Install and tighten the filler bolt to the specified torque. Tightening torque: Oil filler bolt: 23 Nm (2.3 m·kg) 1. Case cover 2.
E_5el_Periodic.fm Page 11 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner as part of routine maintenance. 1. Air filter 2. Projection 3. Slot EC000095 4.
E_5el_Periodic.fm Page 12 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. 1. Throttle stop screw 2. Set the idle to the specified engine speed by adjusting the throttle stop screw.
E_5el_Periodic.fm Page 13 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00647* CE-32E 201 kg (export for G, A, SF) 200 kg (for G, A, SF) Tires Maximum load* To ensure maximum performance, long service, and safe operation, note the following: Cold tire pressure Up to 90 kg* 200 kPa 225 kPa (2.00 kg/cm2, (2.25 kg/cm2, 2.00 bar) 2.25 bar) Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. 90 kg load ~ Maximum load* 225 kPa 250 kPa (2.
E_5el_Periodic.fm Page 14 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR CE-10E EAU00681 FRONT Manufacturer Size Type Bridgestone 110/90-18 61S L309 Dunlop 110/90-18 61S K555F @ REAR Manufacturer Size Type Bridgestone 170/80-15M/C 77S G546 Dunlop 170/80-15M/C 77S K555 CE-26E 1. Side wall a. Tread depth Tire inspection Always check the tires before operating the motorcycle.
E_5el_Periodic.fm Page 15 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 NOTE: If proper adjustment cannot be obtained or the clutch does not work correctly, ask a Yamaha dealer to inspect the internal clutch mechanism. Wheels 6 To ensure maximum performance, long service, and safe operation, note the following: ● Always inspect the wheels before a ride. Check for cracks, bends or warpage of the wheel. Be sure the spokes are tight and undamaged.
E_5el_Periodic.fm Page 16 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary. @ 1. Locknut 2. Adjusting bolt a. Free play EW000099 EAU00696 Front brake lever free play adjustment The free play at the front brake lever should be 5 ~ 8 mm. 1. Loosen the locknut. 2. Turn the adjusting bolt in direction a to increase free play or in direction b to decrease free play. 3.
E_5el_Periodic.fm Page 17 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary. @ a.
E_5el_Periodic.fm Page 18 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Wear indicator groove 1. Wear indicator groove EAU01314 Checking the front and rear brake pads Each brake pad is provided with a wear indicator groove, which allows checking the brake pad for wear without disassembling the brake. Inspect each wear indicator groove and, as soon as one of them has almost worn away, ask a Yamaha dealer to replace the brake pads as a set.
E_5el_Periodic.fm Page 19 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● Have a Yamaha dealer check the cause if the brake fluid level goes down. ● 1. Minimum level mark 1. Minimum level mark EAU00731 Inspecting the brake fluid level 6 Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective.
E_5el_Periodic.fm Page 20 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel.
E_5el_Periodic.fm Page 21 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02984 6 EAU02985 Brake and shift pedal lubrication Brake and clutch lever lubrication Lubricate the pivoting parts. Lubricate the pivoting parts. Recommended lubricant: Engine oil Recommended lubricant: Engine oil EAU02986 Sidestand lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly.
E_5el_Periodic.fm Page 22 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Front fork inspection Visual check EW000115 WARNING Securely support the motorcycle so there is no danger of it falling over. @ @ Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. Operation check 1. Place the motorcycle on a level place. 2. Hold the motorcycle in an upright position and apply the front brake. 3.
E_5el_Periodic.fm Page 23 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 EAU00800 Wheel bearings Battery If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. ● If the battery seems to have discharged, consult a Yamaha dealer.
E_5el_Periodic.fm Page 24 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000102 @ 1. Positive terminal 2. Negative terminal Battery storage When the motorcycle is not used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place. CAUTION: ● Completely recharge the battery before storing. Storing a discharged battery can cause permanent battery damage. ● Use a battery charger designed for a sealed-type (MF) battery.
E_5el_Periodic.fm Page 25 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses: Odometer fuse: Ignition fuse: Headlight fuse: Carburetor heater fuse: Signaling system fuse: 1. 2. 3. 4. 5. 6. Main fuse The main fuse is located under the rider seat. 1. Remove the rider seat. (See page 3-10 for removal and installation procedures.
E_5el_Periodic.fm Page 26 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 After removal CAUTION: Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. Before installation @ @ 1. Ignitor unit panel 2. Spare fuse 3. Main fuse 3. Pull the ignitor unit panel outward to the right. 4.
E_5el_Periodic.fm Page 27 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 1. Bulb holder EAU00833 Headlight bulb replacement 6 This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace the bulb as follows: 1. Remove the headlight unit screws. 2. Remove the connectors, the headlight unit and then the bulb cover. 1. Don’t touch 3. Turn the bulb holder counterclockwise to remove it and remove the defective bulb.
E_5el_Periodic.fm Page 28 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000105 CAUTION: Avoid touching the glass part of a bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on a bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. @ @ 5. Install the bulb cover, connectors and headlight unit. Ask a Yamaha dealer to adjust the headlight beam if necessary. 1.
E_5el_Periodic.fm Page 29 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting 6 Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer.
E_5el_Periodic.fm Page 30 Monday, May 1, 2000 9:44 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01297 Troubleshooting chart EW000125 WARNING Never check the fuel system while smoking or in the vicinity of an open flame. @ @ 1. Fuel Enough fuel. Go to compression check. No fuel. Supply fuel. Check if there is fuel in the fuel tank. Engine doesn’t start, go to compression check. 2. Compression There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect.
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E_5el_CleaningTOC.fm Page 1 Monday, May 1, 2000 9:45 AM MOTORCYCLE CARE AND STORAGE Care ................................................................................................... 7-1 Storage...............................................................................................
E_5el_Cleaning.fm Page 1 Monday, May 1, 2000 9:46 AM MOTORCYCLE CARE AND STORAGE EAU01521 7- Care The exposure of its technology makes a motorcycle charming but also vulnerable. Although high-quality components are used, they are not all rustresistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
E_5el_Cleaning.fm Page 2 Monday, May 1, 2000 9:46 AM MOTORCYCLE CARE AND STORAGE ECA00010 @ CAUTION: ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If you do use such products for hard-to-remove dirt, do not leave it on any longer than instructed, then thoroughly rinse it off with water, immediately dry the area and apply a corrosion protection spray. ● Improper cleaning can damage windshields, cowlings, panels and other plastic parts.
E_5el_Cleaning.fm Page 3 Monday, May 1, 2000 9:46 AM MOTORCYCLE CARE AND STORAGE 1. Clean your motorcycle with cold water and soap after the engine has cooled down. ECA00012 CAUTION: Do not use warm water since it increases the corrosive action of the salt. @ @ 2. Be sure to apply a corrosion protection spray on all (even chromeand nickel-plated) metal surfaces to prevent corrosion. 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2.
E_5el_Cleaning.fm Page 4 Monday, May 1, 2000 9:46 AM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 @ @ CAUTION: ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust.
E_5el_Cleaning.fm Page 5 Monday, May 1, 2000 9:46 AM MOTORCYCLE CARE AND STORAGE 7. Check and, if necessary, correct the tire air pressure, then raise the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover up the muffler outlets with plastic bags to prevent moisture from entering. 9. Remove the battery and fully charge it.
E_5el_SpecTOC.fm Page 1 Monday, May 1, 2000 9:46 AM SPECIFICATIONS Specifications ..................................................................................... 8-1 HOW TO USE THE CONVERSION TABLE .......................................
E_5el_Spec.
E_5el_Spec.fm Page 2 Monday, May 1, 2000 9:47 AM SPECIFICATIONS Gear ratio Final gear oil Type SAE80API “GL-4” Hypoid Gear Oil Quantity 0.2 L Air filter Dry type element Fuel Type Regular unleaded gasoline Fuel tank capacity 17 L Reserve amount 4.5 L Type × quantity BSR37 × 2 MIKUNI Frame type Gap Clutch type 2nd 1.667 3rd 1.286 4th 1.032 5th 0.853 Double cradle Caster angle 33° Trail 136 mm Tires Front Spark plug Type/Manufacturer 2.
E_5el_Spec.fm Page 3 Monday, May 1, 2000 9:47 AM SPECIFICATIONS Rear Air pressure (cold tire) Up to 90 kg load* Front Rear 2 200 kPa (2.00 kg/cm , 2.00 bar) 2 225 kPa (2.25 kg/cm , 2.25 bar) Single disc brake Operation Right foot operation Fluid DOT 4 Type Telescopic fork Type Swingarm (link suspention) Suspension 90 kg load ~ maximum load* Front Front 225 kPa (2.25 kg/cm2, 2.25 bar) Rear 250 kPa (2.50 kg/cm2, 2.
E_5el_Spec.fm Page 4 Monday, May 1, 2000 9:47 AM SPECIFICATIONS Headlight type Quartz bulb (halogen) Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Auxiliary light 12 V, 4 W × 1 Tail/brake light 12 V, 5/21 W × 1 Turn signal light 12 V, 21 W × 4 Meter light 14 V, 1.4 W × 2 Oil level indicator light 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 Turn indicator light 12 V, 1.7 W × 1 Engine trouble indicator light 12 V, 1.7 W × 1 High beam indicator light 12 V, 1.
E_5el_Spec.fm Page 5 Monday, May 1, 2000 9:47 AM SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CS-02E CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER METRIC TO IMPERIAL Metric unit IMPERIAL **mm × 0.03937 = **in 2 mm × 0.03937 = 0.08 in 8 8-5 Multiplier Imperial unit Torque m·kg m·kg cm·kg cm·kg 7.233 86.794 0.0723 0.
E_5el_ConsumerTOC.fm Page 1 Monday, May 1, 2000 9:47 AM CONSUMER INFORMATION Identification number records............................................................. 9-1 Key identification number ................................................................... 9-1 Vehicle identification number.............................................................. 9-1 Model label.........................................................................................
E_5el_Consumer.fm Page 1 Monday, May 1, 2000 9:47 AM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 1. Key identification number 1.
E_5el_Consumer.fm Page 2 Monday, May 1, 2000 9:47 AM CONSUMER INFORMATION 1. Model label EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-10 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
E_5elIX.fm Page 1 Monday, May 1, 2000 9:48 AM INDEX 10- A F Air filter ..................................................6-10 Antitheft alarm (optional) ..........................3-4 Final gear oil............................................ 6-9 Front brake lever ..................................... 3-6 Front brake lever free play adjustment... 6-16 Front fork inspection .............................. 6-22 Fuel ......................................................... 3-7 Fuel cock...................
E_5elIX.fm Page 2 Monday, May 1, 2000 9:48 AM INDEX Rear brake pedal ..................................... 3-6 Rear brake pedal height adjustment ...... 6-17 Rear shock absorber adjustment ........... 3-13 Recommended shift points (for Switzerland only)............................. 5-5 Right view................................................ 2-2 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-29 Troubleshooting chart ..............
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 7 - 0.
