OWNER’S MANUAL YZF600RW(C) LIT-11626-20-25 5AH-28199-1B
U5AH1BE0.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha YZF600RW(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM IMPORTANT MANUAL INFORMATION EAU10131 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. *Product and specifications are subject to change without notice.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE YZF600RW(C) OWNER’S MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 Sidestand ..................................... 3-14 Ignition circuit cut-off system ....... 3-15 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 PRE-OPERATION CHECKS .............
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM TABLE OF CONTENTS Lubricating the rear suspension ...6-32 Checking the front fork .................6-32 Checking the steering ...................6-33 Checking the wheel bearings .......6-33 Battery ..........................................6-34 Replacing the fuses ......................6-35 Replacing the headlight bulb ........6-36 Replacing the tail/brake light bulb ...........................................6-37 Replacing a turn signal light bulb ......
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION EAU10272 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION 1 ● ● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 180 kg (397 lb) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
U5AH1BE0.book Page 4 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION 1 ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U5AH1BE0.book Page 5 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5AH1BE0.book Page 6 Thursday, May 18, 2006 3:45 PM SAFETY INFORMATION 1 5 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 1 5JW-00 2 6 Cold tire normal pressure should be set as follows.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM DESCRIPTION EAU10410 Left view 2 8. Grab bar 9. Shift pedal (page 3-6) 10.Radiator (page 6-15) 1. 2. 3. 4. Air intake duct (page 6-20) Fuel tank (page 3-7) Shock absorber assembly spring preload adjusting ring (page 3-12) Shock absorber assembly rebound damping force adjusting knob (page 3-12) 5. Shock absorber assembly compression damping force adjusting screw (page 3-12) 6. Storage compartment (page 3-10) 7.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake pedal (page 3-6) 10.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Throttle grip (page 6-21) 10.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights EAU11080 EAU11320 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.1 L (0.82 US gal) (0.68 Imp.gal). When this occurs, refuel as soon as possible.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11630 Speedometer unit EAU11851 Tachometer EAU11981 Self-diagnosis device This model is equipped with a self-diagnosis device for the following electrical circuits: ● throttle position sensor ● fuel level warning light If any of those circuits are defective, the tachometer will repeatedly display the following error code: 3 1. Odometer 2. Tripmeter reset knob 3.
U5AH1BE0.book Page 4 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10040 CAUTION: EAU12171 Coolant temperature gauge When the tachometer displays an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. EAU12346 Handlebar switches Left 3 1. Coolant temperature gauge 2. Coolant temperature gauge red zone With the key in the “ON” position, the coolant temperature gauge indicates the temperature of the coolant.
U5AH1BE0.book Page 5 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 EAU12820 Clutch lever CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12460 3 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
U5AH1BE0.book Page 6 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU12930 Brake lever EAU12941 Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Shift pedal 1.
U5AH1BE0.book Page 7 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13070 Fuel tank cap EAU13211 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Fuel tank cap lock cover 2. Unlock. 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank.
U5AH1BE0.book Page 8 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 19.0 L (5.02 US gal) (4.18 Imp.gal) Fuel reserve amount: 3.1 L (0.82 US gal) (0.68 Imp.gal) knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel.
U5AH1BE0.book Page 9 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13920 EAU14290 Seat Helmet holder To remove the seat 1. Insert the key into the helmet holder lock, and then turn it as shown. 3 1. Seat holder 2. Projection 2. Push the rear of the seat down to lock it in place. 3. Remove the key. 1. Unlock. 2. Pull the seat off. NOTE: Make sure that the seat is properly secured before riding. To install the seat 1.
U5AH1BE0.book Page 10 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14451 Storage compartment When washing the vehicle, be careful not to let any water enter the storage compartment. EAU14741 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws. EWA10180 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 1.
U5AH1BE0.book Page 11 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b). Rebound damping force Compression damping force 1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a).
U5AH1BE0.book Page 12 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.
U5AH1BE0.book Page 13 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force 3 1. Rebound damping force adjusting knob To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob in direction (b).
U5AH1BE0.book Page 14 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. EAU15190 Luggage strap holders EAU15301 Sidestand The sidestand is located on the left side of the frame.
U5AH1BE0.book Page 15 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U5AH1BE0.book Page 16 Thursday, May 18, 2006 3:45 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM 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.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-7 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-12 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-21, 6-30 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM OPERATION AND IMPORTANT RIDING POINTS ● 5 ● is pushed, and they should go off when the start switch is released. If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting ECA10260 CAUTION: Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ● 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U5AH1BE0.book Page 4 Thursday, May 18, 2006 3:45 PM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U5AH1BE0.book Page 5 Thursday, May 18, 2006 3:45 PM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17200 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● ● Keep the engine speed out of the tachometer red zone.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 6 ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold.
U5AH1BE0.book Page 4 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with solvent. • Replace if necessary. 2 * Clutch • Check operation. • Adjust or replace cable.
U5AH1BE0.book Page 5 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assemblies for looseness.
U5AH1BE0.book Page 6 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage.
U5AH1BE0.book Page 7 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 25 * Throttle grip housing and cable • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable. 26 * Lights, signals and switches • Check operation. • Adjust headlight beam.
U5AH1BE0.book Page 8 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18781 Removing and installing cowlings The cowlings shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling needs to be removed and installed. 1. Cowling C 2. Cowling D 1. Screw EAU42330 Cowlings A and C 6 To remove one of the cowlings 1. Remove the screws. 1. Cowling A 2. Cowling B 1. Screw 2.
U5AH1BE0.book Page 9 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the grab bar by removing the bolts. 3. Remove the screw, and then pull the cowling off as shown. 6 1. Turn signal light lead connector 1. Screw To install the cowling 1. Connect the turn signal light lead connectors. 2. Place the cowling in the original position, and then install the screws. NOTE: Pull the cowling up, then back to remove it. EAU19050 Cowling B To remove the cowling 1. Remove the seat.
U5AH1BE0.book Page 10 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19544 NOTE: If any spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. Checking the spark plugs The spark plugs are important engine components, which are easy to check.
U5AH1BE0.book Page 11 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19672 NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. Canister (for California only) 4. Install the spark plug cap. 1. Spark plug gap Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 6 2.
U5AH1BE0.book Page 12 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Make sure the vent hose is not blocked. Clean it if necessary. EAU19911 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1.
U5AH1BE0.book Page 13 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. NOTE: An oil filter wrench is available at a Yamaha dealer. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1.
U5AH1BE0.book Page 14 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11620 Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) CAUTION: ● 8. Install the engine oil drain bolt, and then tighten it to the specified torque. NOTE: Check the washer for damage and replace it if necessary. Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 9. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.
U5AH1BE0.book Page 15 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 ECA10471 Coolant CAUTION: The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. ● ● EAU20144 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position.
U5AH1BE0.book Page 16 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10380 NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 6-43 for further instructions. EAU20412 To change the coolant 1. Place the vehicle on a level surface and let the engine cool if necessary. 2. Remove the seat. (See page 3-9.) 3. Remove cowlings A, C and D. (See page 6-8.) 4.
U5AH1BE0.book Page 17 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 12. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. 13. Install the coolant reservoir by installing the screws. 14. Install the water pump drain bolt and cylinder drain bolts, and then tighten them to the specified torques. 1. Water pump drain bolt 2. Cylinder drain bolt 10. Remove the coolant reservoir by removing the screws.
U5AH1BE0.book Page 18 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 19. Check the coolant level in the reservoir. If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap. 20. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. 21. Install the right air intake duct, and then tighten the clamp screws. 22.
U5AH1BE0.book Page 19 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10420 NOTE: The sponge material should be wet but not dripping. WARNING ● Recommended oil: Yamaha foam air filter oil or other quality foam air filter oil 1. Air filter element 8. Insert the air filter element into the air filter case. ECA10480 6. Clean the air filter element with solvent, and then squeeze the remaining solvent out. 6 CAUTION: ● ● 7.
U5AH1BE0.book Page 20 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21200 Checking the air vent hose EAU21210 Air intake duct EAU21271 Carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. 1. Air vent hose 1.
U5AH1BE0.book Page 21 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21381 Checking the throttle cable free play EAU21401 EAU21750 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U5AH1BE0.book Page 22 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) 90–180 kg (198–397 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.
U5AH1BE0.book Page 23 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Tire information ● 1. Tire air valve 2. Tire air valve core 3. Tire air valve cap with seal 6 This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10480 WARNING ● ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed.
U5AH1BE0.book Page 24 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21960 Cast wheels To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
U5AH1BE0.book Page 25 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22020 Adjusting the clutch lever free play EAU22270 NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. 1. Locknut 2. Clutch lever free play adjusting bolt 3. Clutch lever free play 6 Adjusting the rear brake light switch 1. Rear brake light switch 2.
U5AH1BE0.book Page 26 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22311 Checking the front and rear brake pads Front brake 1. Brake pad wear indicator The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake.
U5AH1BE0.book Page 27 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level.
U5AH1BE0.book Page 28 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 NOTE: Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same position for proper wheel alignment. Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22771 To check the drive chain slack 1. Place the motorcycle on the sidestand.
U5AH1BE0.book Page 29 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then tighten the axle nut to the specified torque. Tightening torque: Axle nut: 117 Nm (11.7 m·kgf, 85 ft·lbf) EAU23022 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.
U5AH1BE0.book Page 30 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23091 EAU23111 EAU23131 Checking and lubricating the cables Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
U5AH1BE0.book Page 31 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 EAUM1650 Checking and lubricating the sidestand Lubricating the swingarm pivots The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
U5AH1BE0.book Page 32 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23250 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U5AH1BE0.book Page 33 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
U5AH1BE0.book Page 34 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23370 Battery This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. ● ECA10620 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery. EWA10760 ● • EYES: Flush with water for 15 minutes and seek prompt medical attention.
U5AH1BE0.book Page 35 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23624 Replacing the fuses 6 1. 2. 3. 4. 5. Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Spare fuse The main fuse and the fuse box, which contains the fuses for the individual circuits, are located under the seat. (See page 3-9.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2.
U5AH1BE0.book Page 36 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU23740 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Disconnect the headlight coupler, and then remove the bulb cover. 1. Headlight bulb holder EWA10790 WARNING 1. Headlight coupler 2. Headlight bulb cover 2. Unhook the headlight bulb holder, and then remove the defective bulb. Headlight bulbs get very hot.
U5AH1BE0.book Page 37 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the headlight bulb cover, and then connect the coupler. 5. Have a Yamaha dealer adjust the headlight beam if necessary. 6 EAU24131 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 1. Screw EAU24202 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1. Screw 2.
U5AH1BE0.book Page 38 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.
U5AH1BE0.book Page 39 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the front fender by removing the screws. 3. Loosen the front wheel axle pinch bolt, then the wheel axle and the brake caliper bolts. 6. Remove the brake calipers on each side by removing the bolts. 7. Pull the wheel axle out, remove the speedometer gear unit, and then remove the wheel.
U5AH1BE0.book Page 40 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the wheel axle, then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques. EAU25080 Rear wheel EAU25222 To remove the rear wheel EWA10820 Tightening torques: Wheel axle: 65 Nm (6.5 m·kgf, 47 ft·lbf) Front wheel axle pinch bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf) 8. Install the front fender by installing the screws. 9.
U5AH1BE0.book Page 41 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 3. Lift the rear wheel off the ground according to the procedure on page 6-38. 4. Remove the axle nut and the left wheel axle guide, and then remove the brake caliper by removing the bolts. 5. Disconnect the brake torque rod from the brake caliper bracket by removing the nut and the bolt. 6. Loosen the locknut and the drive chain slack adjusting nut on both sides of the swingarm. 7.
U5AH1BE0.book Page 42 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Tightening torques: Axle nut: 117 Nm (11.7 m·kgf, 85 ft·lbf) Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf) Brake torque rod nut: 30 Nm (3.0 m·kgf, 22 ft·lbf) 6. Install a new cotter pin into the brake torque rod bolt. EWA11280 WARNING Always use a new cotter pin for the brake torque rod bolt.
U5AH1BE0.book Page 43 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU42310 Troubleshooting charts Starting problems or poor engine performance EWA10840 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. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank.
U5AH1BE0.book Page 44 Thursday, May 18, 2006 3:45 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWAT1040 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. 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.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26011 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM MOTORCYCLE CARE AND STORAGE ● ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26160 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U5AH1BE0.book Page 4 Thursday, May 18, 2006 3:45 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. °C (90 °F)]. For more information on storing the battery, see page 6-34. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM SPECIFICATIONS Dimensions: Overall length: 2060 mm (81.1 in) Overall width: 725 mm (28.5 in) Overall height: 1190 mm (46.9 in) Seat height: 805 mm (31.7 in) Wheelbase: 1415 mm (55.7 in) Ground clearance: 135 mm (5.31 in) Minimum turning radius: 3200 mm (126.0 in) Weight: With oil and fuel: 214.0 kg (472 lb) Engine: 8 Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined parallel 4-cylinder Displacement: 599.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM SPECIFICATIONS Operation: Left foot operation Gear ratio: 1st: 37/13 (2.846) 2nd: 37/19 (1.947) 3rd: 34/22 (1.545) 4th: 28/21 (1.333) 5th: 25/21 (1.190) 6th: 29/27 (1.074) Chassis: Frame type: Diamond Caster angle: 25.00 ° Trail: 97.0 mm (3.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM SPECIFICATIONS Charging system: AC magneto Battery: Model: YTX12-BS Voltage, capacity: 12 V, 10.0 Ah Headlight: Headlight fuse: 20.0 A Signaling system fuse: 15.0 A Ignition fuse: 7.5 A Radiator fan fuse: 7.5 A Bulb type: Halogen bulb Bulb voltage, wattage × quantity: 8 Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8.0 W/27.0 W × 1 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-9.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5AH1BE0.book Page 3 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5AH1BE0.book Page 5 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U5AH1BE0.book Page 7 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26662 YAMAHA MOTOR CORPORATION, U.S.A.
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U5AH1BE0.book Page 9 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5AH1BE0.book Page 10 Thursday, May 18, 2006 3:45 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U5AH1BE0.book Page 1 Thursday, May 18, 2006 3:45 PM INDEX A F Accessories and replacement parts ..... 6-24 Air filter element, cleaning .................... 6-18 Air intake duct ....................................... 6-20 Air vent hose, checking ........................ 6-20 B Battery .................................................. 6-34 Brake and clutch levers, checking and lubricating ........................................... 6-31 Brake and shift pedals, checking and lubricating .................
U5AH1BE0.book Page 2 Thursday, May 18, 2006 3:45 PM INDEX Throttle cable free play, checking ......... 6-21 Throttle grip and cable, checking and lubricating ........................................... 6-30 Tires ...................................................... 6-21 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-42 Troubleshooting charts ......................... 6-43 Turn signal indicator light ........................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.05-0.
