brake pads YAMAHA YZF1000 2000 Owners Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Cowling removal and installation .......................... 6-5
Cowling A.............................................................. 6-5
Cowling B.............................................................. 6-5
Cowling C ............................................................. 6-6
Spark plugs........................................................... 6-7
Engine oil .............................................................. 6-9
Coolant ............................................................... 6-11
Air filter ............................................................... 6-12
Carburetor adjustment ........................................ 6-14
Idle speed adjustment ........................................ 6-15
Throttle cable free play inspection ...................... 6-15
Valve clearance adjustment ................................ 6-16
Tires .................................................................... 6-16
Wheels................................................................ 6-19
Brake light switch adjustment ............................. 6-19
Checking the front and rear brake pads.............. 6-20
Inspecting the brake fluid level............................ 6-21
Brake fluid replacement ...................................... 6-22
Drive chain slack check ...................................... 6-23Drive chain slack adjustment ............................. 6-23
Drive chain lubrication........................................ 6-24
Cable inspection and lubrication ........................ 6-24
Brake and shift pedal lubrication ........................ 6-24
Brake and clutch lever lubrication ...................... 6-25
Sidestand lubrication.......................................... 6-25
Rear suspension lubrication............................... 6-25
Front fork inspection ........................................... 6-26
Steering inspection ............................................ 6-26
Wheel bearings .................................................. 6-27
Battery................................................................ 6-27
Fuse replacement .............................................. 6-28
Headlight bulb replacement ............................... 6-29
Tail/brake light bulb replacement ........................ 6-30
Turn signal light bulb replacement...................... 6-30
Front wheel removal ........................................... 6-31
Front wheel installation ...................................... 6-31
Rear wheel removal ........................................... 6-32
Rear wheel installation ....................................... 6-33
Troubleshooting .................................................. 6-34
Troubleshooting chart......................................... 6-35
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
CP-01ENO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.
• Replace if necessary.ÖÖ
2*Fuel filter• Check condition.
• Replace if necessary.Ö
3 Spark plugs• Check condition.
• Clean, regap or replace if necessary.ÖÖÖ
4*Valves• Check valve clearance.
• Adjust if necessary.Every 42,000 km or 42 months
(whichever comes first)
5 Air filter
• Clean or replace if necessary.ÖÖ
6*Clutch• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly. ÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
9*Wheels• Check balance, runout and for damage.
• Rebalance or replace if necessary.ÖÖ
10*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖ
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU00715
Checking the front and rear
brake padsA wear indicator is provided on each
brake. This indicator allows checking of
brake pad wear without disassembling
the brake. Apply the brake and inspect
the wear indicator. If the indicator is AL-
MOST in contact with the disc plate,
ask a Yamaha dealer to replace the
pads.1. Wear indicatorFront
1. Wear indicatorRear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU01800
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake or clutch system, possibly
causing them to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and fill
when necessary. Low brake fluid levels
may indicate worn brake pads and/or
brake system leakage. If the brake lev-
el is low, be sure to inspect the brake
pads for wear or brake system for leak-
age.Observe these precautions:
l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
l
Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake or clutch
performance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake or clutch perfor-
mance.
1. Minimum level markFront brake
1. Minimum level markClutch
1. Minimum level markRecommended brake fluid: DOT 4Rear brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU01252*
Front wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Remove the speedometer cable
from the front wheel side.
2. Remove the front fender bolts and
front fender.3. Loosen the pinch bolt, wheel axle
and caliper bolts.
4. Elevate the wheel.
5. Remove the brake hose holders
and calipers.
NOTE:@ Do not depress the brake lever when
the calipers are off the discs as the
brake pads will be forced shut. @6. Remove the wheel axle and
speedometer gear unit. Make sure
the motorcycle is properly support-
ed.
EAU01469*
Front wheel installation1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the pro-
jections meshed into the slots.
2. Lift up the wheel between the front
fork legs. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork outer
tube.
3. Install the wheel axle and let the
motorcycle down.
1. Speedometer cable
2. Front fender bolt (´ 4)
3. Front fender
4. Caliper bolt (´ 2)
5. Brake hose holder
1. Pinch bolt
2. Wheel axle
3. Caliper bolt (´ 2)
1. Speedometer gear unit
2. Slot
3. Stopper
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 4. Install the calipers, caliper bolts
and brake hose holders. Make
sure there is enough gap between
the brake pads before installing
the calipers onto the brake discs.
5. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torques.
6. Push down hard on the handle-
bars several times to check for
proper fork operation.
7. Install the speedometer cable.
8. Install the front fender and bolts.
EAU01247*
Rear wheel removal
EW000122
WA R N I N G
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Loosen the axle nut and caliper
bolts.
2. Elevate the rear wheel.3. Remove the axle nut, caliper bolts
and caliper.
4. Loosen the locknuts on each side
of the swingarm.
5. Turn the chain adjusting bolts fully
outward.
6. Push the wheel forward and re-
move the drive chain.
7. Pull out the wheel axle and re-
move the wheel assembly by pull-
ing backwards. Tightening torque:
Wheel axle:
72 Nm (7.2 m·kg)
Pinch bolt:
23 Nm (2.3 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)1. Axle nut
2. Adjusting bolt
3. Locknut
1. Caliper bolt (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
NOTE:@ l
Do not depress the brake pedal
when the caliper is off the disc as
the brake pads will be forced shut.
l
You do not have to disassemble
the chain in order to remove or in-
stall the rear wheel.
@
EAU01246*
Rear wheel installation1. Install the wheel assembly, caliper
bracket and insert the axle.
2. Install and adjust the drive chain.
(See page 6-23 for details about
adjusting the drive chain slack.)
3. Install the axle nut and let the
motorcycle down.
4. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
5. Tighten the axle nut and caliper
bolts to the specified torques.1. Caliper bracket
Tightening torque:
Axle nut:
150 Nm (15.0 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)
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10-INDEXAAir filter ..................................................6-12BBattery ................................................... 6-27
Brake and clutch lever lubrication........... 6-25
Brake and shift pedal lubrication ............ 6-24
Brake fluid replacement ......................... 6-22
Brake light switch adjustment ................. 6-19CCable inspection and lubrication ............ 6-24
Carburetor adjustment ...........................6-14
Care.........................................................7-1
Checking the front and rear brake
pads ....................................................6-20
Clutch lever .............................................. 3-9
Controls/Instruments ................................2-3
Coolant ..................................................6-11
Coolant temperature gauge ..................... 3-7
Cowling A ................................................6-5
Cowling B ................................................6-5
Cowling C ................................................6-6
Cowling removal and installation .............. 6-5DDiagnosis device......................................3-7
Dimmer switch .........................................3-8
Drive chain lubrication ............................6-24
Drive chain slack adjustment..................6-23
Drive chain slack check.......................... 6-23EEngine break-in........................................ 5-5
Engine oil ................................................. 6-9
Engine stop switch................................... 3-9
EXUP (EXhaust Ultimate Powervalve)... 3-19FFront brake lever ................................... 3-10
Front fork adjustment............................. 3-15
Front fork inspection .............................. 6-26
Front wheel installation .......................... 6-31
Front wheel removal .............................. 6-31
Fuel ....................................................... 3-12
Fuel indicator circuit check....................... 3-5
Fuel indicator light ................................... 3-4
Fuel tank breather hose
(for Germany only) .............................. 3-13
Fuel tank cap ......................................... 3-11
Fuse replacement.................................. 6-28GGive safety the right of way ..................... 1-1HHandlebar switches ................................. 3-8
Dimmer switch ................................... 3-8
Engine stop switch ............................. 3-9
Horn switch ........................................ 3-8
Lights switch ...................................... 3-9
Pass switch ........................................ 3-8
Start switch ........................................ 3-9
Turn signal switch .............................. 3-8
Headlight bulb replacement ................... 6-29
Helmet holder ........................................ 3-14
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-8
IIdentification number records ...................9-1
Idle speed adjustment ............................6-15
Indicator lights ..........................................3-2
Fuel indicator light...............................3-4
High beam indicator light ....................3-2
Neutral indicator light ..........................3-2
Oil level indicator light .........................3-2
Turn indicator light ..............................3-2
Inspecting the brake fluid level ...............6-21KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ............................................3-9
Luggage strap holders ...........................3-19MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level indicator circuit check .................3-3
Oil level indicator light ..............................3-2PParking.....................................................5-6
Pass switch ..............................................3-8
Periodic maintenance and lubrication .......6-2
Pre-operation check list............................. 4-1
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