Keep flammable products or your hands away from the bulb while it is on, as it is hot. Do not touch the bulb until it cools down.

4. Slip a new bulb into position and secure
it in place with the bulb holder

5. Reinstall the light unit assembly and head­
light cow!. Adjust the headlight beam if
necessary.

6-43

Headlight beam adjustment

U-343

For the headlight beam adjustment, be sure to proceed as follows (it is advisable to have a Yamaha dealer make this ad­justment).

1. Horizontal adjustment: (Except for
Oceania) eaj2moq

To adjust the beam to the left, turn the Front wheel removal

adjusting screw clockwise

To adjust the beam to the right, turn the

screw counterclockwise.

2. Vertical adjustment:

To raise the beam, turn the adjusting screw clockwise.

To lower the beam, turn the screw coun­terclockwise.

6-44

1 Disc cover

4. Loosen the wheel axle holder nuts.

5. Remove the axle and the front wheel.
Make sure the motorcycle is properly sup­
ported.

EUU05400

NOTE: _____________________________

Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced shut.

3 Remove the speedometer cable.

J-234

Front wheel installation

When installing the front wheel, reverse the

removal procedure.

Pay attention to the following points: 1. Make sure the wheel hub and the speedometer clutch assembly are installed with the projections meshed into the slots.

1 Speedometer cable 2 Axle holder nut 3 Wheel axle

6-45

2. Make sure the projecting portion (torque stopper) of the speedometer housing is positioned correctly.

3. Make sure the axle is properly torqued.

Tightening torque:

58 Nm (5.8 m.kg, 42 ft-lb)

4. Before tightening the holder nuts, com­
press the front forks several times to
check for proper fork operation.

5. Tighten the axie holder nuts; first the up­
per and then lower ones.

6-46

Axle holder nut torque:

10 Nm (1.0 nvkg, 7.2 ft-lb)

EAJ36800

Rear wheel removal

EUU6620O

AWARNIWG:

It is advisable to have a Yamaha dealer service the rear wheel.

1. Cotter pin 2 Axle nut 3. Chain puller

3. Push the wheel forward and remove the drive chain.

1. Elevate the rear wheel by placing a suita­
ble stand under the engine.

2. Remove the cotter pin from the axle nut
and loosen the axle nut.

6-47

4. Remove the axle nut.

5. The rear wheel assemble, the collar the
chain pullers, etc., can be removed from
the motorcycle by pulling the wheel axle

EULT05500

NOTE: _____________________________

Do not depress the brake pedal when the disc is off the caliper as the brake pads wiil be forced shut.

J-367

Rear wheel installation

When installing the rear wheel, reverse the removal procedure. Pay attention to the follow­ing points:

1. Adjust the drive chain.

2. Make sure the axle nut is properly toqued,
and a new cotter pin is installed.

U-647

\WARNING:

Always use a new cotter pin on the axle nut.

Axle nut torque:

90 Nm {9.0 m.kg, 65 ft-lb)

J 500

Troubleshooting

Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for checking these sys­tems. If your motorcycle requires any repair, bring it to a Yamaha dealer. The skilled tech­nicians at a Yamaha dealer ship have the tools, experience, and know-how to properlyservice your motorcycle. Use only genuine Yamaha parts on your motorcycle. Imitations parts may look like Yamaha parts, but they are often in­ferior. Consequently, they have a shorter serv­ice life and can lead to expensive repair bills.

6-48

J-614

Troubleshooting chart

U-663

iiWARNING:

Never check the fuel system while smoking or in the vicinity of an open flame.

Remove the fuel pipe and check fuel flow

Fuel flow

Water or dirt mixed in fuel

No irregularity up to fuel cock

Clean filter element and fuel tank

1. Fuel

\ There is fuelh

Turn the fuel cock to "OFF"

[Fuel cock clogged

Check if there is fuel in the fuel tank

2. Compression

] Some fuel

No fuel

Turn the fuel cock to "RES"

Supply fuel

| Restart engine

T

Turn the fuel cock to "ON"

Kick the kick lever to see if there is compression

\ There is compression} —» {Compression normal |

Ask Yamaha dealer to inspect

3. Ignition

Remove plug and check electrode

Wipe clean with dry cloth

Restart engine

Ask Yamaha dealer to inspect

6-49

CLEANING AND STORAGE

K009

A. CLEANING

Frequent thorough cleaning of your motorcy­cle will not only enhance its appearance but will improve its general performance and ex­tend the useful life of many components.

1. Before cleaning the motorcycle:

a. Block off the end of the exhaust pipe to
prevent water entry; a plastic bag and
strong rubber band may be used.

b. Make sure the spark plug(s) and all filler
caps are properly installed.

2. If the engine case is excessively greasy,
apply degreaser with a paint brush. Do
not apply degreaser to the chain, sprock­
ets, or wheel axles

3. Rinse the dirt and degreaser off with a
garden hose. Use only enough pressure
to do the job

U 346

Excessive hose pressure may cause water seepage and contamination of wheel bear­ings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure de­tergent applications such as those availa­ble in coin-operated car washers.

4 Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places.

5. Rinse the motorcycle off immediately with
clean water and dry all surfaces with a
chamois, clean towel, or soft absorbent
cloth.

6. Dry the chain and lubricate it to prevent
rust.

7-1

7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.

8. Automotive-type wax may be applied to
all painted and chrome-plated surfaces.
Avoid combination cleaner-waxes. Many
contain abrasives which may mar the
paint or protective finish. When finished,
start the engine and let it idle for several
minutes.

K-010

B. STORAGE

Long term storage (60 days or more) of your motorcycle wili require some preventive proce­dures to guard against deterioration. After thoroughly cleaning the motorcycle, prepare for storage as follows: 1. Drain the fuel tank, fuel lines, and carbu­retor float bowl(s).

2. Remove the empty fuel tank, pour a cup
of SAE 10W30 or 20W40 motor oil in the
tank, shake the tank to coat the inner sur­
faces thoroughly and drain off the excess
oil. Reinstall the tank.

3. Remove the spark plug(s), pour about one
tablespoon of SAE 10W30 or 20W40 mo­
tor oil in the spark plug hole(s) and rein­
stall the spark plug(s). Kick the engine
over several times (with the ignition off)
to coat the cylinder walls with oil.

4. Remove the drive chain. Thoroughly clean
the chain with kerosene and lubricate it.
Reinstall the chain or store it in a plastic
bag (tied to frame for safe-keeping),

5. Lubricate all control cables.

6. Block up the frame to raise both wheels
off the ground.

7. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.

7-2

If storing in a humid or salt-air at­mosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex­cessively warm or cold place (less than 0°C{30°F) or more than 30°C(90°F)).

U-058

NOTE: _____________________________

Make any necessary repairs before storing the motorcycle.

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