E_4YP_Intro0.fm Page 1 Wednesday, October 6, 1999 10:01 AM INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a XVZ1300A, 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 XVZ1300A’s advantages.
E_4YP_Info0.fm Page 1 Wednesday, October 6, 1999 10:13 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_4YP_Info0.fm Page 2 Wednesday, October 6, 1999 10:13 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_4YP_Info0.fm Page 3 Wednesday, October 6, 1999 10:13 AM IMPORTANT MANUAL INFORMATION EAU00008 XVZ1300A OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
E_4YP_Toc0.
E_4YP_Toc0.
E_4YP_LabelTOC.fm Page 1 Wednesday, October 6, 1999 10:02 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY.................................................
E_4YP_Label.fm Page 1 Wednesday, October 6, 1999 10:03 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_4YP_DescriptionTOC.fm Page 1 Wednesday, October 6, 1999 10:03 AM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls/Instruments ..........................................................................
E_4YP_Description.fm Page 1 Wednesday, October 6, 1999 10:03 AM DESCRIPTION EAU00026 2- Left view 2 1. Shift pedal 2. Starter (choke) knob 3. Fuel cock 4. Steering lock 5. Tool kit 6. Seat lock 7. Rear turn signal lights 8. Tail/brake light 9. Mufflers 10.
E_4YP_Description.fm Page 2 Wednesday, October 6, 1999 10:03 AM DESCRIPTION Right view 2 11. Passenger footrest 12. Main switch 13. Passenger seat 14. Helmet holders 15. Rider seat 16. Fuel tank 17. Fuel tank cap 18. Headlight 19. Front turn signal light 20. Rear brake pedal 21. Rider footrest 22.
E_4YP_Description.fm Page 3 Wednesday, October 6, 1999 10:03 AM DESCRIPTION Controls/Instruments 2 1. Clutch lever 2. Left handlebar switches 3. Speedometer 4. Right handlebar switches 5. Throttle grip 6.
E_4YP_FunctionsTOC.fm Page 1 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch......................................................................................... 3-1 Indicator lights .................................................................................... 3-1 Speedometer...................................................................................... 3-3 Antitheft alarm (optional) ....................................................................
E_4YP_Functions.fm Page 1 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- EAU00054* (Parking) The taillight and auxiliary light come on but all other circuits are off. With the key at “OFF”, push it into the main switch, turn it counterclockwise to “ ”, and remove it. To cancel the parking, turn the key clockwise. 3 EAU00028 EAU00056 Main switch Indicator lights The main switch controls the ignition and lighting systems. Its operation is described below.
E_4YP_Functions.fm Page 2 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00057 EAU01272 4. Turn indicator light “ ” This indicator flashes when the turn switch is moved to the left or right. 7. Overdrive / Engine trouble indicator light “O/D / ” ● This indicator light will come on when the transmission is in overdrive (5th gear). ● This indicator light will also come on or flash if trouble occurs in an engine monitoring circuit.
E_4YP_Functions.fm Page 3 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Antitheft alarm (optional) An antitheft alarm can be equipped to this motorcycle. Consult your Yamaha dealer to obtain and install the alarm. 3 1. “TRIP” button 2. Odometer/Trip meter EAU01202 Speedometer This speedometer is equipped with an odometer and a trip meter. Pushing the “TRIP” button will change the display from one to the other.
E_4YP_Functions.fm Page 4 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00127 3. 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. EAU00118 Handlebar switches EAU00119 EAU00129 4. Horn switch “ ” Press the switch to sound the horn. 1.
E_4YP_Functions.fm Page 5 Wednesday, October 6, 1999 10:03 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. Clutch lever EAU00138 EAU00152 Clutch lever 1. Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system.
E_4YP_Functions.fm Page 6 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Shift pedal 1. Front brake lever EAU01215 EAU00158 EAU00162 Shift pedal Front brake lever Rear brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. Use your toe or heel to shift up and your toe to shift down. The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.
E_4YP_Functions.fm Page 7 Wednesday, October 6, 1999 10:03 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_4YP_Functions.fm Page 8 Wednesday, October 6, 1999 10:03 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: closed position ON: normal position @ @ EAU00191 3 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 18 L Reserve: 3.
E_4YP_Functions.fm Page 9 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS RES: reserve position 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. Fill the tank at the first opportunity. Be sure to set the fuel cock back to “ON” after refueling! 1.
E_4YP_Functions.fm Page 10 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering 1. Open the steering lock cover. 2. Insert the key, turn it counterclockwise 1/8 turn, and let go of it. (It automatically moves to where it can be removed.) 3. Remove the key and close the steering lock cover. 3 On the right side of the headpipe, there is also a place to lock the steering with a padlock.
E_4YP_Functions.fm Page 11 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Helmet holder (× 2) 1. Helmet holding cable EAU01636 Helmet holders There are two helmet holders under the rider seat. To secure a helmet on the right side holder, simply hook the buckle of the helmet strap over the holder and close the seat securely. To secure a helmet on the left side holder, use the helmet holding cable located beside the tool kit.
E_4YP_Functions.fm Page 12 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: In order to check or adjust the air pressure, the motorcycle must be elevated so the front wheel is not in contact with the ground. @ @ EW000037 WARNING Each fork leg must be set to the same pressure. Uneven setting can cause poor handling and loss of stability. @ 1. Air valve EAU01605 Adjusting front fork preload 3 Minimum/standard air pressure setting: Zero Maximum air pressure setting: 50 kPa (0.
E_4YP_Functions.fm Page 13 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Special wrench EAU01694 Adjusting rear shock absorber preload 1. Locknut 2. Adjusting nut A. Distance “A” 1. Loosen the locknut. This shock absorber is equipped with a spring preload adjusting nut. Use the special wrench located in the owner’s tool kit to adjust the spring preload. 3-13 2. Turn the adjusting nut in direction a to increase spring preload and in direction b to decrease spring preload.
E_4YP_Functions.fm Page 14 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. ● Take your shock absorber to a Yamaha dealer for any service. ● Spring preload: Minimum (soft): Distance “A” = 48.5 mm Standard: Distance “A” = 45.5 mm Maximum (hard): Distance “A” = 40.5 mm @ 3 EC000015 CAUTION: Never attempt to turn an adjuster beyond the maximum or minimum setting.
E_4YP_Functions.fm Page 15 Wednesday, October 6, 1999 10:03 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand 3 This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) EW000044 WARNING This motorcycle must not be operated with the sidestand in the down position.
E_4YP_PreopTOC.fm Page 1 Wednesday, October 6, 1999 10:04 AM PRE-OPERATION CHECKS Pre-operation check list......................................................................
E_4YP_Preop.fm Page 1 Wednesday, October 6, 1999 10:04 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_4YP_Preop.fm Page 2 Wednesday, October 6, 1999 10:04 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_4YP_OperationTOC.fm Page 1 Wednesday, October 6, 1999 10:04 AM OPERATION AND IMPORTANT RIDING POINTS Starting the engine............................................................................. 5-1 Starting a warm engine ...................................................................... 5-3 Shifting ............................................................................................... 5-3 Tips for reducing fuel consumption ....................................................
E_4YP_Operation.fm Page 1 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU01588 Starting the engine NOTE: This motorcycle is equipped with a starting and an ignition circuit cut-off switch. The engine can be started only under one of the following conditions: ● The transmission is in neutral. ● The sidestand is up, the transmission is in gear, and the clutch is disengaged. The motorcycle must not be ridden when the sidestand is down.
E_4YP_Operation.fm Page 2 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “ ”. 4. Turn on the starter (choke) and completely close the throttle grip. 5. Start the engine by pushing the starter switch. EC000037 CAUTION: If the fuel level indicator light comes on, check the fuel level. If necessary, add fuel. @ @ 3. Shift transmission into neutral.
E_4YP_Operation.fm Page 3 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS 6. After starting the engine, move the starter (choke) to the halfway position. 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 @ @ 7. After the engine is warm, turn off the starter (choke) completely.
E_4YP_Operation.fm Page 4 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS EC000048 @ @ CAUTION: ● Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. ● Always use the clutch when changing gears.
E_4YP_Operation.fm Page 5 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS 500 ~ 1,000 km Avoid cruising speeds in excess of 3/4 throttle. EAU00436 Engine break-in 5 There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km. For this reason we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first 1,000 km.
E_4YP_Operation.fm Page 6 Wednesday, October 6, 1999 10:05 AM OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking 5 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.
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E_4YP_PeriodicTOC.fm Page 1 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit...................................................................6-1 Periodic maintenance and lubrication...................6-3 Spark plugs...........................................................6-6 Engine oil ..............................................................6-7 Final gear oil .......................................................6-10 Coolant .....................................
E_4YP_Periodic.fm Page 1 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- RONMENT. The most important points of motorcycle inspection, adjustment, and lubrication are explained in the following pages. EW000060 WARNING If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer. @ @ 1.
E_4YP_Periodic.fm Page 2 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. @ @ EW000063 WARNING Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
E_4YP_Periodic.fm Page 3 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E EVERY NO. 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.
E_4YP_Periodic.fm Page 4 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. ITEM 10 Tires * 11 * Wheel bearings Swingarm 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ √ • Check bearing for looseness or damage. • Replace if necessary. √ √ • Check swingarm pivoting point for play. • Correct if necessary.
E_4YP_Periodic.fm Page 5 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. 6 ITEM CHECKS AND MAINTENANCE JOBS √ √ √ • Check oil level and vehicle for oil leakage. • Correct if necessary. • Change. (Warm engine before draining.) √ √ √ * Carburetors 21 Engine oil 22 Engine oil filter cartridge • Replace. * Cooling system 24 Final gear oil 12,000 km or 12 months (whichever comes first) • Check engine idling speed, synchronization and starter operation.
E_4YP_Periodic.fm Page 6 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Spark plug cap 1. Spark plug wrench EAU01485 Spark plugs Removal 1. Remove the spark plug cap. 2. Use the spark plug wrench in the tool kit to remove the spark plug as shown. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.
E_4YP_Periodic.fm Page 7 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kg) 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 Installation 1.
E_4YP_Periodic.fm Page 8 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Stop the engine and wait for a few minutes. Check the oil level through the level window located at the lower part of the right 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. If the level is low, fill the engine with sufficient recommended oil to reach the specified level. 1.
E_4YP_Periodic.fm Page 9 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Fill the engine with sufficient recommended oil. Install the oil filler cap and tighten it. Recommended oil: See page 8-1. Oil quantity: Total amount: 4.3 L Periodic oil change: 3.5 L With oil filter replacement: 3.7 L 1. Oil filter 7. Install the new oil filter and tighten it to the specified torque with an oil filter wrench.
E_4YP_Periodic.fm Page 10 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Final gear oil filler bolt 2. Final gear oil drain bolt EAU01589 EAU01220 Final gear oil Check for oil leakage. If any leakage is found, take the motorcycle to a Yamaha dealer for repairs. Coolant 1. Remove the reservoir tank cover by removing the screw. 2. Check the coolant level in the reservoir tank when the engine is cold as the coolant level will vary with engine temperature.
E_4YP_Periodic.fm Page 11 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 Carburetor adjustment 1. Reservoir tank cap 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.
E_4YP_Periodic.fm Page 12 Wednesday, October 6, 1999 10:05 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_4YP_Periodic.fm Page 13 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000082 EW000083 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed.
E_4YP_Periodic.fm Page 14 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000079 WARNING Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. @ 1. Sidewall a. Tread depth Tire inspection Always check the tires before operating the motorcycle.
E_4YP_Periodic.fm Page 15 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000132 WARNING After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd. for this model. No guarantee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design. Always use the tire valves and valve cores listed below.
E_4YP_Periodic.fm Page 16 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● After repairing or replacing the rear tire, tighten the valve stem nut and locknut to the specified torque. Tightening torque: Valve stem nut: 1.6 Nm (0.16 m·kg) Valve stem locknut: 1.6 Nm (0.16 m·kg) EAU00695 Clutch lever free play adjustment This motorcycle has a hydraulic clutch.
E_4YP_Periodic.fm Page 17 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 @ 1. Locknut 2. Adjusting bolt c. Free play EAU00696 6 Front brake lever free play adjustment The free play at the front brake lever should be 2 ~ 5 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. After adjusting, tighten the locknut. WARNING ● Check the brake lever free play.
E_4YP_Periodic.fm Page 18 Wednesday, October 6, 1999 10:05 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. @ @ 1.
E_4YP_Periodic.fm Page 19 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR Front Rear 1. Wear indicator groove (× 2) 1. Wear indicator groove EAU00721 Checking the front and rear brake pads EAU01119 6 Front brake Wear indicator grooves are provided on each brake pad. These indicators allow checking of brake pad wear without disassembling the brake. Inspect the grooves. If they have almost disappeared, ask a Yamaha dealer to replace the pads. 1.
E_4YP_Periodic.fm Page 20 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Minimum level mark Observe these precautions: ● When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars. ● Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake or clutch performance.
E_4YP_Periodic.fm Page 21 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel. Have the Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking: ● oil seals (every two years) ● brake hoses (every four years) EAU02984 Brake and shift pedal lubrication Lubricate the pivoting parts.
E_4YP_Periodic.fm Page 22 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02985 EAU02986 Brake and clutch lever lubrication Sidestand lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Lubricate the pivoting parts. Recommended lubricant: Engine oil Recommended lubricant: Engine oil EW000113 WARNING If the sidestand does not move smoothly, consult a Yamaha dealer.
E_4YP_Periodic.fm Page 23 Wednesday, October 6, 1999 10:05 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. 6 1. Battery 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_4YP_Periodic.fm Page 24 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000101 EW000116 CAUTION: Never try to remove the sealing caps of the battery cells. The battery will be damaged. WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. ANTIDOTE: ● EXTERNAL: Flush with water. ● INTERNAL: Drink large quantities of water or milk.
E_4YP_Periodic.fm Page 25 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw EAU01702 Fuse replacement 6 Sub fuse box The sub fuse box is located behind the upper left side panel. To remove the panel, remove the screw and pull the panel outward. 1. 2. 3. 4. 5. 6. Ignition fuse Signaling system fuse Headlight fuse Fan fuse Odometer fuse Spare fuse (× 3) Specified fuses: Ignition fuse: Signaling system fuse: Headlight fuse: Fan fuse: Odometer fuse: 6-25 1.
E_4YP_Periodic.fm Page 26 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR If any fuse is blown, turn off the main switch and the switch of the circuit in question. Install a new fuse of specified amperage. Turn on the switches and see if the electrical device operates. If the fuse immediately blows again, consult a Yamaha dealer. 1. Main fuse 2. Spare fuse EC000103 CAUTION: Do not use fuses of higher amperage rating than those recommended.
E_4YP_Periodic.fm Page 27 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 1. Connector (× 3) 2. Remove the connectors, the headlight unit and then the bulb cover. 3. Turn the bulb holder counterclockwise to remove it and remove the defective bulb. 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.
E_4YP_Periodic.fm Page 28 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting 1. Screw (× 2) 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.
E_4YP_Periodic.fm Page 29 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02990* 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.
E_4YP_Periodic.fm Page 30 Wednesday, October 6, 1999 10:05 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Engine overheating EW000070 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. Open the radiator cap as follows. Wait until the engine has cooled. Remove the radiator cap stopper by removing the screw.
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E_4YP_CleaningTOC.fm Page 1 Wednesday, October 6, 1999 10:06 AM MOTORCYCLE CARE AND STORAGE Care ................................................................................................... 7-1 Storage...............................................................................................
E_4YP_Cleaning.fm Page 1 Wednesday, October 6, 1999 10:06 AM MOTORCYCLE CARE AND STORAGE EAU01521 7- Care 7 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_4YP_Cleaning.fm Page 2 Wednesday, October 6, 1999 10:06 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_4YP_Cleaning.fm Page 3 Wednesday, October 6, 1999 10:06 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_4YP_Cleaning.fm Page 4 Wednesday, October 6, 1999 10:06 AM MOTORCYCLE CARE AND STORAGE ECA00013 @ CAUTION: ● Apply spray oil and wax sparingly and wipe off any excess. ● Never apply oil or wax on rubber and plastic parts, but treat them with a suitable care product. ● Avoid using abrasive polishing compounds as they wear away the paint. @ NOTE: Consult a Yamaha dealer for advice on what products to use.
E_4YP_Cleaning.fm Page 5 Wednesday, October 6, 1999 10:06 AM MOTORCYCLE CARE AND STORAGE a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs and place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e.
E_4YP_SpecTOC.fm Page 1 Wednesday, October 6, 1999 10:06 AM SPECIFICATIONS Specifications ..................................................................................... 8-1 How to use the conversion table ........................................................
E_4YP_Spec.
E_4YP_Spec.fm Page 2 Wednesday, October 6, 1999 10:06 AM SPECIFICATIONS Final gear oil Type Quantity SAE80API “GL-4” Hypoid Gear Oil Transmission type Constant mesh 5-speed Operation Left foot operation Gear ratio 0.2 L Radiator capacity (including all routes) Air filter 2.9 L Dry type element Fuel Type Regular unleaded gasoline Fuel tank capacity 18 L Reserve amount 3.5 L BDS28 × 4 Manufacturer MIKUNI Gap Clutch type 1.579 3rd 1.160 4th 0.906 5th 0.
E_4YP_Spec.fm Page 3 Wednesday, October 6, 1999 10:06 AM SPECIFICATIONS Maximum load* 203 kg Rear Air pressure (cold tire) Up to 90 kg load* 2 Front 250 kPa (2.50 kg/cm , 2.50 bar) Rear 250 kPa (2.50 kg/cm2, 2.50 bar) Rear Right foot operation Fluid DOT 4 Type Telescopic fork Type Swingarm (link suspension) Front 250 kPa (2.50 kg/cm2, 2.50 bar) 2 280 kPa (2.80 kg/cm , 2.80 bar) Rear * Load is the total weight of cargo, rider, passenger and accessories.
E_4YP_Spec.fm Page 4 Wednesday, October 6, 1999 10:06 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 lights 12 V, 21 W × 4 Meter light 14 V, 1.4 W × 2 Neutral indicator light 12 V, 1.7 W × 1 High beam indicator light 12 V, 1.7 W × 1 Oil level indicator light 12 V, 1.7 W × 1 Turn indicator light 12 V, 1.
E_4YP_Spec.fm Page 5 Wednesday, October 6, 1999 10:06 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_4YP_ConsumerTOC.fm Page 1 Wednesday, October 6, 1999 10:07 AM CONSUMER INFORMATION Identification number records............................................................. 9-1 Key identification number ................................................................... 9-1 Vehicle identification number.............................................................. 9-1 Model label.........................................................................................
E_4YP_Consumer.fm Page 1 Wednesday, October 6, 1999 10:07 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: 1. Key identification number CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 1.
E_4YP_Consumer.fm Page 2 Wednesday, October 6, 1999 10:07 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_4YPIX.fm Page 1 Wednesday, October 6, 1999 10:07 AM INDEX 10- A Adjusting front fork preload ....................3-12 Adjusting rear shock absorber preload ................................................3-13 Antitheft alarm (optional) ..........................3-3 B Battery ...................................................6-23 Brake and clutch lever lubrication...........6-22 Brake and shift pedal lubrication ............6-21 Brake fluid replacement .........................
E_4YPIX.fm Page 2 Wednesday, October 6, 1999 10:07 AM INDEX S V Shifting .................................................... 5-3 Shift pedal ............................................... 3-6 Sidestand .............................................. 3-15 Sidestand/clutch switch operation check .................................................. 3-15 Sidestand lubrication ............................. 6-22 Spark plugs ............................................. 6-6 Specifications .......................