Handlebar switches

EAU03888
Dimmer switch / Set this switch to for the high beam and to for the low beam.

EAU04218

NOTE: The self-canceling system only operates when the motorcycle is moving, so that the turn signal lights will not selfcancel while you are stopped at an intersection.

EAU00129

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.
Horn switch Press this switch to sound the horn.
Engine stop switch / Set this switch to before starting the engine. Set this switch to to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck.

EAU00143

Start switch Push this switch to crank the engine with the starter.

EC000005

CAUTION: See page 5-1 for starting instructions prior to starting the engine.

1. Clutch lever

EAU00152

1. Shift pedal

EAU01215

1. Brake lever

EAU00158

Clutch lever

The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-17 for an explanation of the ignition circuit cut-off system.)

Shift pedal

The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. NOTE: Use your toes or heel to shift up and your toes to shift down.

Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.
To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward. 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover.

1. Brake pedal

EAU00162

Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.

1. 2. a. b.

Fuel tank cap lock cover mark Unlock. Lock.

EAU02917

Fuel tank cap
To remove the fuel tank cap Slide the lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed.
NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked.

Engine oil

6-96-12

Front brake

6-216-25

Rear brake

6-226-25

Clutch

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. 4-1
ITEM Control cables CHECKS Make sure that operation is smooth. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE

Wheels and tires

6-186-20
Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch
Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivot if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle.

6-28 6-29 6-29 3-17

NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

EWA00033

WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
OPERATION AND IMPORTANT RIDING POINTS
Starting and warming up a cold engine.. 5-1 Starting a warm engine... 5-3 Shifting.... 5-3 Engine break-in... 5-5 Parking.... 5-6

EAU00372

Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

EAU00376

EAU01751*
Starting and warming up a cold engine

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.

EAU00423

Shifting
5 Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.
CAUTION: Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.
NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.

EAU02988* EAU02974

To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. 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. NOTE: Always shift gears at the recommended shift points.
Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below.

CF-04E

Acceleration shift point mi/h (km/h)
Deceleration shift point mi/h (km/h)

EAU00427

To decelerate 1. Apply both the front and the rear brakes to slow the motorcycle. 2. Shift the transmission into first gear when the motorcycle reaches 16 mi/h (25 km/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle. 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

1st 2nd 3rd 4th

2nd 3rd 4th 5th
13 (20) 19 (30) 25 (40) 31 (50)
16 (25) 16 (25) 16 (25) 16 (25)

EAU01128

Engine break-in
There is never a more important period in the life of your engine than the period between 0 and 1,000 mi (1,600 km). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,000 mi (1,600 km). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.
1,000 mi (1,600 km) and beyond The vehicle can now be operated normally.

EC000049

CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

EAU01740*

0600 mi (01,000 km) Avoid prolonged operation 1/3 throttle.
6001,000 mi (1,0001,600 km) Avoid prolonged operation above 1/2 throttle.

ECA00026*

CAUTION: After 600 mi (1,000 km) of operation, the engine oil and transfer case oil must be changed, and the oil filter cartridge replaced.

EAU00457

Parking
When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to OFF.

EW000058

WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the motorcycle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance..6-1 Owners tool kit..6-2 Periodic maintenance chart for the emission control system...6-3 General maintenance and lubrication chart.6-4 Removing and installing the panel..6-7 Checking the spark plugs.6-8 Canister (for California only)..6-9 Engine oil and oil filter cartridge.6-9 Transfer case oil..6-13 Cleaning the air filter element..6-15 Adjusting the carburetor..6-17 Adjusting the throttle cable free play.6-17 Adjusting the valve clearance..6-17 Tires...6-18 Spoke wheels..6-20 Accessories and replacement parts.6-20 Adjusting the clutch lever free play..6-21 Adjusting the brake lever free play.6-21 Adjusting the brake pedal position.6-22 Adjusting the rear brake light switch.6-23 Checking the front and rear brake pads.6-23 Checking the brake fluid level.. 6-24 Changing the brake fluid.. 6-25 Drive belt slack.. 6-25 Checking and lubricating the throttle grip and cable... 6-27 Checking and lubricating the brake and shift pedals.. 6-28 Checking and lubricating the brake and clutch levers.. 6-29 Checking and lubricating the sidestand. 6-29 Checking the front fork.. 6-30 Checking the steering.. 6-31 Checking the wheel bearings.. 6-31 Battery... 6-32 Replacing the fuses.. 6-33 Replacing the headlight bulb.. 6-35 Replacing a turn signal light bulb or the tail/brake light bulb. 6-37 Supporting the motorcycle.. 6-37 Troubleshooting.. 6-38 Troubleshooting chart.. 6-39

* * * * * * *

Sidestand pivot Sidestand switch Front fork

Steering bearings

Lithium soap base grease
Wheel bearings Rear suspension link pivots Drive belt
Molybdenum disulfide grease -
Every 2,500 mi (4,000 km)

EAU03907

NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.

EAU03057

NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake system When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. Replace the brake hoses every four years or if cracked or damaged.

1. Panel A

EAU01777

1. Bolt

EAU00491
Removing and installing the panel
6 The panel shown above needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed.
Panel A To remove the panel Remove the bolt, and then pull the panel off as shown.
To install the panel Place the panel in the original position, and then install the bolt.
The porcelain insulator around the center electrode of each spark plug should be a medium-to-light tan (the ideal color when the motorcycle is ridden normally), and all spark plugs installed in the engine should have the same color. If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced. Specified spark plug: DPR7EA-9/NGK or X22EPR-U9/DENSO Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. Spark plug gap: 0.030.04 in (0.80.9 mm)
Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. Tightening torque: Spark plug: 12.5 ftlbf (1.75 mkgf, 17.5 Nm) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

a. Spark plug gap

EAU01639

Checking the spark plugs

The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.

ECA00021

CAUTION: Do not use any tools to remove or install the spark plug cap, otherwise the ignition coil coupler may get damaged. The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly. To remove the spark plug cap, simply twist it back and forth while pulling it out; to install it, twist it back and forth while pushing it in.

1. Engine oil filler cap

EAU00499 EAU04628
Canister (for California only)
This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this motorcycle, make sure to check the following: Check each hose connection. Check each hose and canister for cracks or damage. Replace if damaged. Make sure that the canister breather is not blocked, and if necessary, clean it.
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. Place the motorcycle on a level surface and hold it in an upright position.
NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.
NOTE: When adding oil, be careful not to overfill the engine; the oil level rises faster starting from the half level portion on the dipstick.
2. Remove the rider seat. (See page 3-11 for rider seat removal and installation procedures.) 3. Start the engine, warm it up until the engine oil has reached a normal temperature of 140 F (60 C), let it continue to idle for ten seconds, and then turn the engine off. NOTE: To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first completely cooled down, and then warmed up again for several minutes to normal operating temperature.

EWA00011

198 lb (90 kg) maximum

CE-16E

Maximum load*
tribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (windshield, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury.
* Total weight of rider, passenger, cargo and accessories

EWA00012

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,
WARNING Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and dis_
combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design.

EAU00680

CE-10E
FRONT Manufacturer Dunlop Size 130/90-16 67H 130/90-16 M/C 67H 130/90-16 67H 130/90-16 M/C 67H Model D404FL
1. Tire sidewall 2. Tire wear indicator a. Tire tread depth
Bridgestone REAR Manufacturer Dunlop
Tire inspection Always check the tires before operating the motorcycle. If a tire tread shows crosswise line (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced.

EW000078

Size 150/80B-16 71H 150/80B-16 M/C 71H 150/80B-16 71H 150/80B-16 M/C 71H

Model D404

Bridgestone

CE-23E

Minimum tire tread depth (front and rear)

0.04 in (1.0 mm)

WARNING It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product.

1. Locknut 2. Brake lever free play adjusting bolt c. Brake lever free play

EAU00696

Adjusting the brake lever free play
The brake lever free play should measure 0.080.2 in (25 mm) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting bolt in direction a. To decrease the brake lever free play, turn the adjusting bolt in direction b.

3. Tighten the locknut.

EW000099

EW000109

WARNING After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
a. Distance between brake pedal and footrest

EAU01746

Adjusting the brake pedal position
The top of the brake pedal should be positioned approximately 3.9 in (100 mm) above the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, have a Yamaha dealer adjust it.
WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.

EAU00721

Checking the front and rear brake pads
The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
1. Rear brake light switch 2. Rear brake light switch adjusting nut

EAU00713

1. Brake pad wear indicator groove ( 2)

EAU03938

Adjusting the rear brake light switch
6 The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a. To make the brake light come on later, turn the adjusting nut in direction b.
Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set.

Rear Front Rear

1. Brake pad wear indicator groove

EAU03939

1. Minimum level mark

EAU03294

Rear brake pads Each rear brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. 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 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. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4
Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.
Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EAU03976

Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. Oil seals: Replace every two years. Brake hoses: Replace every four years.
1. Drive belt 2. Marks a. Drive belt slack

EAU04452

Drive belt slack
The drive belt slack should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart. To check the drive belt slack 1. Place the motorcycle on a level surface and hold it in an upright position. 2. Note the current position of the drive belt using the marks near the drive belt check hole. NOTE: The marks near the drive belt check hole are 0.2 in (5 mm) apart.

1. Belt tension gauge

1. Wheel axle nut

EAU01748

1. Brake caliper bracket bolt
3. Note the position of the drive belt with a force of 10 lbf (4.5 kg, 45 N) applied to the belt with a belt tension gauge as shown. NOTE: A belt tension gauge is available at a Yamaha dealer.
To adjust the drive belt slack 1. Loosen the rear wheel axle nut and the brake caliper bracket bolt. 6
4. Calculate the drive belt slack by subtracting the measurement noted in step 2 from the measurement noted in step 3. Drive belt slack: 0.30.5 in (7.513 mm) 5. If the drive belt slack is incorrect, adjust it as follows.

ECA00025 EAU04034

CAUTION: Improper drive belt slack will overload the engine. Keep the drive belt slack within the specified range.
Checking and lubricating the throttle grip and cable
The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
5. Tighten the axle nut and the brake caliper bracket bolt to the specified torques.
1. Drive belt slack adjusting bolt ( 2) 2. Locknut ( 2) 3. Wheel axle
2. Loosen the drive belt puller locknut on each side of the swingarm. 3. To tighten the drive belt, turn the adjusting bolt on each side of the swingarm in direction a. To loosen the drive belt, turn the adjusting bolt on each side of the swingarm in direction b, and then push the rear wheel forward. NOTE: Turn each adjusting bolt the same amount for proper wheel alignment.
Tightening torques: Axle nut: 108.5 ftlbf (15 mkgf, 150 Nm) Brake caliper bracket bolt: 34.7 ftlbf (4.8 mkgf, 48 Nm)

4. Tighten the locknuts.

EAU03370
Checking and lubricating the brake and shift pedals
The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6

EAU03164

EAU03165
Checking and lubricating the brake and clutch levers
6 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease)
Checking and lubricating the sidestand

WARNING Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quantities of water or milk and immediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.
To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with optional electrical accessories. To store the battery 1. If the motorcycle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals.

EC000102

CAUTION: keep the battery Always charged. Storing a discharged battery can cause permanent battery damage. To charge a sealed-type (MF) battery, a special (constantvoltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.

EAU04190*

Replacing the fuses
The main fuse and the fuse box, which contains the fuses for the individual circuits, are located behind panel A. (See page 6-7 for panel removal and installation procedures.)

1. 2. 3. 4. 5. 6.

Signaling system fuse Ignition fuse Headlight fuse Carburetor heater fuse Odometer fuse Spare fuse ( 3)
If a fuse is blown, replace it as follows. 1. Turn the key to OFF and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage.

EC000103

CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.
1. Main fuse 2. Spare main fuse
Specified fuses: Main fuse: Headlight fuse: Signaling system fuse: Ignition fuse: Odometer fuse: Carburetor heater fuse:
30 A 15 A 10 A 15 A 5A 10 A
3. Turn the key to ON and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 6

EAU03708

ECA00010
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. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.
CAUTION: Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.
1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.

Quantity Without oil filter cartridge replacement With oil filter cartridge replacement Total amount (dry engine) Transfer case oil Type Quantity Air filter Fuel Type Fuel tank capacity Reserve amount Carburetor Manufacturer Model quantity Spark plug Manufacturer/model Gap Clutch type NGK / DPR7EA-9 or DENSO / X22EPR-U9 0.030.04 in (0.80.9 mm) Wet, multiple-disc Manufacturer/ model MIKUNI BSRUNLEADED GASOLINE ONLY 5.3 US gal (4.4 lmp gal, 20 L) 0.9 US gal (0.8 lmp gal, 3.5 L) Chassis Frame type Caster angle Trail Tire Front Type Size Tube tire 130/90-16 67H 130/90-16 M/C 67H Dunlop / D404FL Bridgestone / G703F 8-2 Double cradle 32 5.6 in (142 mm) SAE80API GL-4 Hypoid Gear Oil 0.42 US qt (0.35 lmp qt, 0.4 L) Dry type element 3.9 US qt (3.3 lmp qt, 3.7 L) 4.3 US qt (3.6 lmp qt, 4.1 L) 5.3 US qt (4.4 lmp qt, 5.0 L) Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th 2.438 1.579 1.160 0.906 0.750 Spur gear 1.532 Belt 2.320 Constant mesh 5-speed Left foot
Rear Type Size Tube tire 150/80B-16 71H 150/80B-16 M/C 71H Manufacturer/ model Brakes Dunlop / D404 Bridgestone / G702 Maximum load* XV16A(C)/XV16ALE(C)/ XV16AS(C) XV16AT(C)/XV16ATLE(C) Tire air pressure (measured on cold tires) Up to 198 lb (90 kg)* Front Rear 198 lb (90 kg)maximum* 36 psi (2.50 kgf/cm2, 250 kPa) 36 psi (2.50 kgf/cm , 250 kPa)
Rear Type Size Spoke wheel 16 MT 3.M/C MT 3.50 Front Type Operation 432 lb (196 kg) 399 lb (181 kg) Rear Type Operation Fluid Suspension Front Rear 36 psi (2.50 kgf/cm , 250 kPa) 41 psi (2.80 kgf/cm2, 280 kPa) Spring/Shock absorber Front Rear Wheel travel Front Type Size Spoke wheel 16 MT 3.M/C MT 3.00 8-3 Rear 5.5 in (140 mm) 4.3 in (110 mm) Coil spring / oil damper Coil spring / gas-oil damper Telescopic fork Swingarm (link suspension) Single disc brake Right foot DOT 4 Fluid Dual disc brake Right hand DOT 4

Front Rear

* Total weight of rider, passenger, cargo and accessories Wheels Front
Electrical Ignition system Charging system Type Standard output Battery Type Voltage, capacity Headlight type Bulb voltage, wattage quantity Headlight Tail/brake light Front turn signal / Front position light Rear turn signal light Meter lighting Neutral indicator light High beam indicator light Turn indicator light Fuel level warning light Engine trouble warning light 12 V, 60/55 W V, 8/27 W V, 27/8 W V, 27 W V, 0.6 W V, 1 W V, 1 W V, 1 W 1 LED 1 LED 1 YTX20L-BS 12 V, 18 Ah Quartz bulb (halogen) A.C. magneto 14 V, 21 A @ 5,000 r/min Transistorized coil ignition (digital) Fuses Main fuse Ignition fuse Signaling system fuse Headlight fuse Carburetor heater fuse Odometer fuse 30 A 15 A 10 A 15 A 10 A 5A

CONSUMER INFORMATION

Identification numbers... 9-1 Key identification number... 9-1 Vehicle identification number... 9-1 Model label... 9-2 Reporting safety defects.. 9-3 Motorcycle noise regulation.. 9-4 Maintenance record... 9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY.. 9-7 YAMAHA EXTENDED SERVICE (Y.E.S.)... 9-9

MOTORCYCLE

1/9/2004

M2004-001

2004 YAMAHA MOTOR CORPORATION, U.S.A.

RECALL

This modification has top priority. This bulletin must be performed immediately to ensure customer safety.
2001~2003 XV16 MODELS FACTORY MODIFICATION CAMPAIGN
Yamaha Motor Corporation, U.S.A., has determined that a defect which relates to motor vehicle safety exists in certain 2001 XV16 (Road Star, Midnight Star, and Road Star Silverado) model motorcycles, and in 2002 and 2003 XV16 (Road Star, Road Star Limited Edition, Midnight Star, and Road Star Silverado) motorcycles. In affected motorcycles, certain transmission components may not meet Yamaha quality-control standards, which could allow abnormal wear that eventually results in a broken retaining circlip. If the circlip breaks, the transmission could lock up, which would also cause the rear wheel to lock up. This could result in loss of control and a vehicle crash with injury or death. To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected motorcycles must have certain transmission components replaced with new ones. Yamaha is notifying all registered owners of affected motorcycles by mail. A copy of this letter is included in this bulletin. The customer should take the letter along with the affected motorcycle to an authorized Yamaha dealer for the modification. A computer report listing all affected motorcycles invoiced to your dealership is included with this bulletin. Use the list to help ensure all motorcycles are modified. All sold motorcycles that have been registered with Yamaha will show the customers name and address. Your dealership must notify the owner of any affected motorcycle that was actually sold but is listed as unsold in the report. You must modify all affected motorcycles in your inventory as well as all customer-owned motorcycles brought to you for this service. Any affected motorcycle that you purchase from Yamaha in the future will also require modification. If you purchase a motorcycle from another dealer, check to see if the procedures in this bulletin have already been performed before you sell the motorcycle. Motorcycles that are affected should not be operated until they are modified. It is a violation of Yamaha policy for your dealership to deliver any affected motorcycles to customers until the procedures in this bulletin are performed. When the modification on each motorcycle is performed, follow the Warranty Information section of this bulletin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 8 of the Warranty and Y.E.S. Handbook (LIT-11760-00-03).

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Modify: Parts Required: Warranty:
All XV16 motorcycles in the affected range.
Yes. Order one 4th Pinion Gear Exchange Kit for each unit. Factory Modification Campaign. See the Warranty Information section of this bulletin.
Notify Customers: Yes. You must immediately contact any customer whose motorcycle shows as unregistered on the enclosed report. Yamaha has sent letters to customers whose motorcycles were registered for warranty as of 1/8/04
2001 Models XV16AN VP02E-015196~016113 XV16ASN VP02E-014871~016033 XV16ATN VP07E-006069~007073
2002 Models XV16AP XV16APC XV16ASP XV16ASPC XV16ATP XV16ATPC

All All All All All All

2003 Models XV16AR XV16ARC XV16ALER XV16ALERC XV16ASR XV16ASRC XV16ATR XV16ATRC
All All All All All All All All
Use the XV1600 service manual (LIT-11616-1256) for information on engine removal, disassembly, re-assembly, and installation. The information contained in this section will give you tips or short cuts on certain procedures to help you work efficiently. For example, when disassembling the engine to access the transmission, it is not necessary to remove the camshafts, lifters, or stator assembly. Review the tips and become familiar with them before beginning work.

PREPARATION Properly secure the motorcycle on a suitable lift. Drain the oil from the engine, reservoir tank, and transfer case. Remove the fuel tank, exhaust system, fuel system, drive system, etc. to prepare for engine removal. Lay the components out in order of removal and keep all the fasteners separated for each component to ease re-assembly. CAUTION: Avoid accidental cosmetic damage. Place components such as fuel tank, side covers, and other easily damaged components in a secure and protected area. Take special care when removing and installing accessories.

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TIPS Side Cover Removal: Before attempting to remove the right side cover, remove the left cover first to access the hidden 6mm bolt.

HIDDEN 6mm SCREW

6mm BOLT
Fuel Pump and Carburetor Removal: Disconnect the carburetor fuel line hose at the fuel pump. Disconnect the fuel pump wire coupler. Remove the choke cable from fuel pump bracket. Remove the upper engine mount, leaving the fuel pump attached to the mount. Disconnect the TPS and carburetor wire couplers. Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws.
UPPER ENGINE MOUNT/ FUEL PUMP

CARBURETOR

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Right-Hand Footrest Removal: Disconnect and remove the brake light switch. Remove the forward-most tie wrap around the brake hose and frame. Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting.
UPPER BANJO BOLT FOOTREST ASSEMBLY
Air Injection System (AIS) Removal: Remove the electric starter motor. Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. Remove the three Phillips head screws holding the AIS assembly on the frame. Remove the AIS assembly from the left side.

AIS AIR FILTER

AIS ASSEMBLY

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Transfer Case Removal: Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. Remove the drive pulley cover and remove the drive pulley nut. Loosen the drive belt tension. Remove the drive pulley, inner cover, collar, and O-ring. NOTE: The collar has a bevel on its inside diameter for the O-ring facing inward and a bevel on the outside diameter facing the pulley. Remove the drive and driven sprockets with chain as an assembly. Remove the collar and O-ring. NOTE: Collar has a bevel on its inside diameter that faces inward for the O-ring.

RELAY BRACKET BEVEL ON OUTSIDE DIAMETER

SEALING WASHER

Remove oil tank filler neck. Remove the relay bracket on the right-hand side. NOTE: Leave the relays connected. Simply move them out of the way to allow room for transfer case removal. Slide the transfer case out from the right side.

TRANSFER CASE

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Engine Removal/Installation: When the engine is ready to be removed from the frame, be sure to disconnect all wire connectors and remove the oil filter bracket. Remove all engine mounting bolts and brackets. Protect all right side frame tubes with protective tape or an equivalent to prevent scratches. Insert steel rods in front and rear engine mount holes and with one person on each side of the engine lift the engine up and out to the right. NOTE: Use 7/16" (10mm) steel rod at least 20" long. The steel rods used to compress the rear suspension of ATVs in their shipping crate work well. Engine Tear Down: Place the engine on a work bench or work surface covered with cardboard or other protective material to protect the engine finish. Remove the left-hand generator shaft end cover and remove the generator shaft bolt and washer. Remove the clutch, primary drive gear, shift shaft, shift detent, oil pump gear and oil crossover pipe. NOTE: The right side of the crossover pipe has an O-ring. If the O-ring doesn't come out with the crossover pipe, be sure to remove it while the engine is disassembled. Remove both top ends
GENERATOR SHAFT END COVER STEEL RODS

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NOTE: Do not remove the push rod tubes from the crankcase. Remove only one circlip from the piston for quicker piston pin removal. Remove the right side crankcase bolts (three 8mm and three 6mm) only. NOTE: Do not remove the cam cover or generator cover.
Tilt the engine to the right and rest the cam cover against a block covered with cardboard or other protective material to protect the engine finish. Remove the left-side crankcase bolts (6mm bolts, quantity 15). Align the shift cam segment with the segmentshaped hole in the crankcase. While holding the crankshaft against the right crankcase, remove the left crankcase half. CAUTION: Be sure to hold the crankshaft against the right case half to prevent disengagement of the camshaft drive gear. Remove the shift fork shafts, shift forks, and transmission.

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Main Shaft Modification: Completely disassemble the main shaft. The Washer 7, 5th Pinion Gear 6, and 2nd/3rd Pinion Gear 5 will be reused. Install the components on the new-type Main Shaft 9 in the following order. Lubricate all components with engine oil. Be sure circlips are installed with the sharp edge of the inner diameter facing away from the mating washer. Collar NEW 4th Pinion Gear NEW Washer NEW Circlip NEW 2nd/3rd Pinion Gear Reuse original part 5th Pinion Gear Reuse original part Washer Reuse original part Circlip NEW

NEW 6 DO NOT USE ORIGINAL 3-TANG WASHER 5 NEW 4 NEW 3 NEW 2 NEW 1
WARNING Be sure to use all of the new parts in the kit. Otherwise, the transmission can still fail. Be sure that you are installing the new washer 3. It is thicker than the original and can be easily identified by its six tangs on the inner diameter instead of the three on the original washer.

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Drive Shaft Modification: Remove the circlip and washer from the Drive Shaft, then remove the 1st Wheel Gear and the 4th Wheel Gear. Do not disassemble the rest of the components on the shaft. Install the components on the original Drive Shaft in the following order. Lubricate all components with engine oil. Be sure the circlip is installed with the sharp edge of the inner diameter facing away from the mating washer. 4th Wheel Gear NEW 1st Wheel Gear Reuse original part Washer Reuse original part Circlip NEW
WARNING Be sure to use all of the new parts in the kit. Otherwise, the transmission can still fail.

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Part Number 90891-10117-00
Description 4th Pinion Gear Exchange Kit Axle, Main (4WM-17411-A0-00) Gear, 4th Pinion (5VN-17141-00-00) Collar (90387-281T8-00) Washer (90209-25013-00) Circlip (93410-23056-00) Circlip (93440-28062-00) Gear, 4th Wheel (4NK-17241-02-00) Circlip (93410-25017-00) Circlip (93450-24028-00) Piston Ring Set (34L-11610-00-00) Washer, Lock (90215-25218-00) Gasket, Crankcase Cover1 (5PX-15451-00-00) Gasket, Cyl. Head 2 (4WM-11182-00-00) Gasket, Head Cover 1 (4WM-11193-00-00) Gasket, Head Cover 2( 4WM-11194-00-00) Gasket, Cyl. (4WM-11351-00-00) Gasket, Cyl. Head 1 (4WM-11181-00-00) Gasket, Exhaust Pipe (3EG-14613-00-00) Gasket, Silencer (3XW-14755-00-00) Intake Manifold O-Ring (93210-505A4-00) Gasket 1 (5PX-17929-00-00) Washer, Lock (90215-26241-00) Element Assy, Oil Cleaner (3FV-13440-10-00) O-ring (93210-06667-00) Gasket 2 (4WM-17931-00-00) Washer, Plate (90201-08087-00) Gasket (90430-10171-00)

Qty 2 4

Dealer Cost $79.49
After modifying a unit, make a punch mark above the frame number (VIN) on the steering head pipe as shown in the illustration below.

PUNCH MARK HERE

* JYAVP02Y81A001XXX

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The owner of each warranty-registered affected unit will receive a letter announcing this campaign. The letter has a label that includes the Primary ID and Recall Number. Use this information when submitting for reimbursement as described below. The modification is authorized for all affected motorcycles, both sold and unsold, regardless of ownership or warranty status. You do not need the customers letter to perform the modification or to file for reimbursement. Submit a Recall Request for the transmission replacement as described below using Recall Number 990021. Choose the status M. You will be reimbursed a labor allowance of 9.0 hours, which includes a reimbursement amount for oil and other shop supplies, plus the cost of the 4th Pinion Gear Exchange Kit and your handling fee. YDS: When signed on to YDS, click on the Service Tab, and then Recall Request-Add. This function has recently been improved to allow you to enter multiple Primary IDs for the same recall. Remember that YDS now requires a 7-digit serial number, so use a 0 as the first digit. The system will check your submission instantly to make sure the Primary ID numbers youve entered are valid for the recall. You can check back the next day for your claim numbers to track your credit.

MAIL: Complete a recall Reimbursement Request (LIT-11790-00-97) as shown below:

4 XX X

- - 0 4
If you have any questions about proper procedures for Factory Modification Campaigns, see Chapter 8 in your Warranty and Y.E.S. Handbook (LIT-11760-00-03).

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6555 Katella Avenue, Cypress, California 90630-5101 (714) 761-7300

SAFETY RECALL NOTICE

January 9, 2004
Dear Yamaha Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Yamaha Motor Corporation, U.S.A., has decided that a defect which relates to motor vehicle safety exists in certain 2001 XV16 (Road Star, Midnight Star, and Road Star Silverado) model motorcycles, and in 2002 and 2003 XV16 (Road Star, Road Star Limited Edition, Midnight Star, and Road Star Silverado) motorcycles. Our records show that you own the affected motorcycle shown on the label above. The reason for this recall: In affected motorcycles, certain transmission components may not meet Yamaha quality-control standards, which could allow abnormal wear that eventually results in a broken retaining circlip. If the circlip breaks, the transmission could lock up, which would also cause the rear wheel to lock up. This could result in loss of control and a vehicle crash with injury or death. To correct this defect, your authorized Yamaha dealer will replace certain transmission components with new ones. There will be no charge to you for this procedure. Your dealer will probably need to keep your motorcycle for at least two days to accomplish the required modification Please call your Yamaha dealer to make a service appointment to have this procedure performed. At that same time you can find out how long he expects he will need to keep your motorcycle for this service. Remember to take this letter with you when you take in your Road Star or Midnight Star motorcycle. You should not ride your motorcycle until this modification is performed. If your motorcycles transmission needed a repair previously, you should still have this modification performed now. If those previous transmission repairs were made at your expense, you should ask the servicing Yamaha dealer to contact Yamaha Customer Relations if the failure involved a broken circlip. If you are unable to return to the Yamaha dealer who sold you the motorcycle, this service will be performed by any authorized Yamaha Motorcycle dealer. For the name of a dealer near you, call 1-800-88YAMAHA or visit the Yamaha web site at: www.yamaha-motor.com. If you need help: If, after contacting your dealership, you have questions or concerns which the dealership is unable to answer, please write to Yamaha Motor Corporation, USA Customer Relations Department P.O. Box 6555 Cypress CA 90630 If, after contacting Yamaha Customer Relations, you are still not satisfied that we have done our best to remedy the situation without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh St. SW, Washington, DC 20590 or call the Auto Safety Hotline at 888-327-4236. If you no longer own this Yamaha: If you have sold your motorcycle to another party, please call us toll-free at 1-800-227-5963 with the name and address of the new owner, along with the serial number shown above your name on the address label above.

What Yamaha and your dealer will do:

What you should do now:

Were sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction with our products. Thank you for giving your attention to this important matter. Sincerely, Customer Support Group Yamaha Motor Corporation, USA

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