Yamaha 2008 YZF-R6X Owner'S Manual Download Page 74 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

EAU33891

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the clutch lever free play adjusting
bolt at the clutch lever in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).

NOTE:

If the specified clutch lever free play
cannot be obtained as described
above, proceed as follows.

1. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loos-
en the clutch cable.

2. Loosen the locknut at the crank-

case.

3. To increase the clutch lever free

play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,
turn the adjusting nut in direction
(b).

4. Tighten the locknut.

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

U13S20E0.book Page 23 Thursday, September 13, 2007 2:14 PM

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Summary of Contents for 2008 YZF-R6X

Page 1: ...13S 28199 20 YZF R6X OWNER S MANUAL ...

Page 2: ...U13S20E0 book Page 2 Thursday September 13 2007 2 14 PM ...

Page 3: ...o enjoy all advantages of your YZF R6X The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha deale...

Page 4: ... you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death t...

Page 5: ... 2007 by Yamaha Motor Co Ltd 1st edition September 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U13S20E0 book Page 2 Thursday September 13 2007 2 14 PM ...

Page 6: ...riodic maintenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 7 Checking the spark plugs 6 11 Engine oil and oil filter cartridge 6 12 Coolant 6 15 Air filter element 6 19 Checking the engine idling speed 6 19 Checking the throttle cable free play 6 19 Valve clearance 6 20 Tires 6 20 Cast wheels 6 22 Adjusting the clutch lever free play 6 23 Adjusting the rear brake li...

Page 7: ...rcycle 6 39 Front wheel 6 39 Rear wheel 6 41 Troubleshooting 6 43 Troubleshooting charts 6 44 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U13S20E0 book Page 2 Thursday September 13 2007 2 14 PM ...

Page 8: ... have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motor...

Page 9: ...ld or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exh...

Page 10: ...e extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearanc...

Page 11: ...uate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fal...

Page 12: ...ETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 3 2 1 U13S20E0 book Page 5 Thursday September 13 2007 2 14 PM ...

Page 13: ...SAFETY INFORMATION 1 6 1 U13S20E0 book Page 6 Thursday September 13 2007 2 14 PM ...

Page 14: ...hock absorber assembly compression damping force adjusting bolt for slow compression damping page 3 23 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 23 9 Shift pedal page 3 15 10 Engine oil filter cartridge page 6 12 11 Engine oil drain bolt page 6 12 12 Front fork compression damping force adjusting bolt for fast compres sion damping page 3 21 ...

Page 15: ...age 6 33 7 Air filter element page 6 19 8 Front brake fluid reservoir page 6 25 9 Radiator cap page 6 15 10 Coolant reservoir page 6 15 11 Engine oil filler cap page 6 12 12 Coolant drain bolt page 6 16 13 Engine oil dipstick page 6 12 14 Brake pedal page 3 16 15 Rear brake light switch page 6 24 16 Rear brake fluid reservoir page 6 25 U13S20E0 book Page 2 Thursday September 13 2007 2 14 PM ...

Page 16: ...er page 3 15 2 Left handlebar switches page 3 13 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 7 5 Right handlebar switches page 3 13 6 Brake lever page 3 15 7 Throttle grip page 6 19 U13S20E0 book Page 3 Thursday September 13 2007 2 14 PM ...

Page 17: ...DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and ...

Page 18: ... bow keep it in a safe place and only use it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stal...

Page 19: ...ched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before t...

Page 20: ... is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11361 Fuel level warning light This warning light comes on wh...

Page 21: ...If this occurs have a Yamaha dealer check the vehicle EAU11423 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer ch...

Page 22: ...ding 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 44 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 44 TRIPA C TRIPA C TRIPA C TRIPA C U13S20E0 book Page 6 Thursday S...

Page 23: ...his indicator light and on how to set it EAU38620 Immobilizer system indicator light The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating ...

Page 24: ... control mode Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 16500 r min and above C...

Page 25: ...eturn to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SE LECT button The stopwatch digits will start flashing Release the SE LECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stopwatch 2 Push the SELECT b...

Page 26: ...en if the air intake temperature is set to be displayed the coolant temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed before the temperature Self diagnosis devi...

Page 27: ...th of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the right display indicates any error codes note the code number and then have a Yamaha dealer check the vehi cle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible ...

Page 28: ...level 5 Push the SELECT button to con firm the selected brightness level The control mode changes to the shift timing indicator light activity function To set the shift timing indicator light ac tivity function 1 Push the RESET button to select one of the following indicator light activity settings The indicator light will stay on when activated This setting is selected when the indicator light st...

Page 29: ...set the deactivation function to a higher engine speed than for the activation function otherwise the shift timing indicator light will remain deactivated 1 Push the RESET button to select the desired engine speed for deac tivating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light bright ness function To ...

Page 30: ...verturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12733 Hazard switch With the key i...

Page 31: ...nation with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU33851 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a brake lever position adjusting knob To adjust the distance between the brake lever and the handleb...

Page 32: ... open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover 1 Brake pedal 1 ...

Page 33: ... spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13390 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has bee...

Page 34: ...revent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU39032 Seats Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the ...

Page 35: ...ssenger seat and pull it forward To install the passenger seat 1 Insert the projections on the pas senger seat into the seat holders as shown and then push the front of the seat down to lock it in place 2 Remove the key NOTE Make sure that the seats are properly secured before riding 1 Projection 2 Seat holder 1 Passenger seat lock 2 Unlock 1 Projection 2 Seat holder U13S20E0 book Page 19 Thursday...

Page 36: ...p buckle and then clip the snap hook onto the cable holder as shown 4 Install the passenger seat WARNING EWA14330 Never ride with a helmet attached to a helmet holding cable since the helmet may hit objects causing loss of control and possibly an accident To release a helmet from the helmet holding cable 1 Remove the passenger seat 2 Unfasten the snap hooks from the cable holder and then remove th...

Page 37: ...in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate groove on the ad justing mechanism with the top of the front fork collar Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting screw on each fork leg in direction a To de...

Page 38: ...hanism 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 spec ifications due to small differences in Rebound damping setting Minimum soft 25 click s in direction b Standard 20 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in direction a 1 Compres...

Page 39: ...ion damping and a compression damping force adjusting bolt for slow compression damping CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring i...

Page 40: ...orce and thereby harden the compres sion damping turn the adjusting bolt in direction a To decrease the compres sion damping force and thereby soften the compression damping turn the ad justing bolt in direction b Spring preload setting Minimum soft 1 Standard 4 Maximum hard 9 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 20 click s in direction b Standard 16 click s...

Page 41: ...y damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber 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 per formance Always have a Yamaha dealer service the sho...

Page 42: ...r mance of or damage to the engine EAU15301 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING...

Page 43: ... gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10...

Page 44: ...d down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked...

Page 45: ...ences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle 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 WARNING EWA11150 If any item in the Pre operation check list is not wor...

Page 46: ...t or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 24 6 25 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoi...

Page 47: ...ary 6 20 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 29 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 30 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten ...

Page 48: ...nd up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 27 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11731 The following warning lights and in dicator lights should come on for a few seconds then go off Oil level warning l...

Page 49: ... the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 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 dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication m...

Page 50: ...it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17081 0 1000 km 0 600 mi Avoid prolonged operation above 8300 r min 1000 1600 km 600 1000 mi Avoid prolonged operation above 9900 r min CAUTIO...

Page 51: ...engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U13S20E0 book Page 4 Thursday September 13 2007 2 14 PM ...

Page 52: ...ot familiar with mainte nance work have a Yamaha dealer do it for you EAU17541 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 18 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrenc...

Page 53: ...O ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check opera...

Page 54: ... alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 800 km 500 mi and after washing the motorcycle or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Brak...

Page 55: ... as sembly Check operation and shock ab sorber for oil leakage 24 Rear suspension re lay arm and con necting arm pivoting points Check operation 25 Fuel injection sys tem Adjust synchronization 26 Engine oil Change Check oil level and vehicle for oil leakage 27 Engine oil filter car tridge Replace 28 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years NO ITEM CH...

Page 56: ...0 Moving parts and cables Lubricate 31 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 32 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary 33 Muffler and exhaust pipe Check the screw clamp for loose ness 34 Lights signa...

Page 57: ... 6 Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U13S20E0 book Page 6 Thursday September 13 2007 2 14 PM ...

Page 58: ...in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU44931 Cowlings A and B To remove one of the cowlings 1 Remove the bolts quick fasteners and quick fastener screw 1 Cowling A 1 Cowling B 2 Cowling C 1 Panel A 2 Panel B 2 1 1 Cowling A 2 Bolt 3 Quick fastener 1 Quick fastener 2 3 1 2 2 2 U13S20E0 book Page 7 Thursday September 13 2007 2 14 PM ...

Page 59: ...the slot slide the cowling forward and then remove the re maining projections from the slots as shown 4 Disconnect the turn signal light lead coupler 1 Quick fastener screw 2 Quick fastener 1 Cowling B 2 Bolt 3 Quick fastener 1 Quick fastener 1 Quick fastener screw 2 Quick fastener 1 Cowling A 2 Cowling B U13S20E0 book Page 8 Thursday September 13 2007 2 14 PM ...

Page 60: ...hown 4 Install the bolts quick fasteners and quick fastener screw EAU39092 Cowling C To remove the cowling 1 Remove cowling B and panel B See page 6 7 2 Unfasten the wire harness by pressing on the projection to open the plastic fastener 1 Cowling A 2 Turn signal light lead coupler 1 Cowling B 2 Turn signal light lead coupler 1 Cowling A 2 Turn signal light lead coupler 1 Cowling B 2 Turn signal l...

Page 61: ...he orig inal position and then close the plastic fastener 4 Install the cowling and the panel EAU39060 Panels A and B To remove one of the panels Remove the bolts and then pull the panel off as shown To install the panel Place the panel in the original position and then install the bolts 1 Plastic fastener 2 Projection 3 Wire harness 1 Cowling C 2 Bolt 3 Quick fastener 1 Cowling C 2 Slot 3 Front c...

Page 62: ...ssive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads NOTE If a torque wrench is not available when installing a spark plug a good estimate...

Page 63: ...pstick and wipe it clean insert it back into the hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark remove the engine oil filler cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the ...

Page 64: ...filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 9 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 10 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt 1 Bolt 2 Shif...

Page 65: ...with the specified amount of the recommended engine oil and then install and tighten the oil filler cap NOTE Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci 1 Torque wrench Tigh...

Page 66: ... the engine off and then check the oil level and correct it if necessary 17 Install the cowling EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU39085 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE...

Page 67: ...ant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 44...

Page 68: ...e the coolant reservoir cap and then turn the coolant reservoir upside down to empty it 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant reservoir by in stalling the bolts 11 Connect the radiator hose and then move the hose clamp back to its original position 12 Install the coolant drain bolt and then tighten it to the speci...

Page 69: ...f the coolant will be reduced 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 17 Start the engine and then check the vehicle for coolant leakage If coolant is leaking ...

Page 70: ...Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication chart Start the engine and warm it up for sev eral minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play a...

Page 71: ...bient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pa...

Page 72: ...ve a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience NOTE The tire tread depth limits may differ from ...

Page 73: ... high speed run Always adjust the tire air pres sure according to the operating conditions EAU21960 Cast wheels To maximize the performance durabil ity 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 be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt...

Page 74: ...lt in direction b NOTE If the specified clutch lever free play cannot be obtained as described above proceed as follows 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Loosen the locknut at the crank case 3 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn ...

Page 75: ...vals spec ified in the periodic maintenance and lubrication chart EAU36890 Front brake pads Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches...

Page 76: ...recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance 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 en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and ...

Page 77: ... checked before each ride and adjusted if necessary EAU22773 To check the drive chain slack 1 Place the motorcycle on the side stand NOTE When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure ...

Page 78: ...10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the axle nut to the speci fied torque 4 Tighten the adjusting bolts in direc tion a to their specified torque 5 Tighten the locknuts to their speci fied to...

Page 79: ...nts 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride...

Page 80: ...the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 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 lu bricated if necessary Recommended lubricant Lithium soap based grease U13S20E0 book Page 29 Thursday September 13 2007 2 14 PM ...

Page 81: ... lubricating the sidestand 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 WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lu...

Page 82: ...EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly CAUTION ...

Page 83: ...upport the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If ...

Page 84: ...mpt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a c...

Page 85: ...urn 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 1 Main fuse 2 Fuel injection system spare fuse 3 Fuel injection system fuse 4 Fuse box 1 5 Backup fuse for odometer clock and immo bilizer system 6 ETV Electronic Throttle Valve fuse 7 Spare fuse 1 Fuse box 2 2 Left radiator fan fuse 3 Right radiator fan ...

Page 86: ...system EAU39010 Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Remove the headlight bulb cover by turning it counterclockwise 2 Disconnect the headlight coupler Specified fuses Main fuse 50 0 A Fuel injection system fuse 15 0 A Electronic throttle valve fuse 7 5 A Backup fuse 7 5 A Radiator fan fuse 15 0 A 2 Ignit...

Page 87: ...ulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than...

Page 88: ...bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break 1 Screw 1 Turn signal light bulb U13S20E0 book Pag...

Page 89: ... it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws EAU44940 Auxiliary light This model is equipped with an LED type auxiliary light If the auxiliary light does not come on have a Yamaha dealer check it 1 Screw 1 License plate light bulb 2 License plate light unit 1 Auxiliary light ...

Page 90: ...frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU33922 To remove the front w...

Page 91: ...tall the brake calipers by install ing the bolts and then tightening them to the specified torque NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders by installing the bolts and nuts 6 Tighten the axle bolt to the speci fied torque NOTE While tightening the axle bolt hold the wheel axle with a ...

Page 92: ...n EAU25080 Rear wheel EAU44950 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut 1 Front wheel axle pinch bolt A 2 Front wheel axle pinch bolt B 3 Front wheel axle pinch bolt C 4 Front wheel axle pinch bolt D Tightening torque Wheel axle pinch bolt ...

Page 93: ...gh to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU39171 To install the rear wheel 1 Install the wheel and the bra...

Page 94: ... for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts...

Page 95: ...here is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starte...

Page 96: ... press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leak...

Page 97: ...cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the driv...

Page 98: ...se 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 After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads ...

Page 99: ...om mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA11130 Make sure that there is no oil or wax on the brakes or tires If...

Page 100: ...he electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the...

Page 101: ...artridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 30 L 2 43 US qt 2 02 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 3 L 4 57 US gal 3 81 Imp gal Fuel reserve amount ...

Page 102: ... Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Righ...

Page 103: ...ED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 7 5 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 1...

Page 104: ...fication number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your moto...

Page 105: ...YSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such de...

Page 106: ...acing 6 35 Helmet holding cable 3 20 High beam indicator light 3 4 Horn switch 3 14 I Identification numbers 9 1 Ignition circuit cut off system 3 27 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 38 Luggage strap holders 3 25 M Main switch steering lock 3 2...

Page 107: ...oubleshooting charts 6 44 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 37 Turn signal switch 3 14 V Valve clearance 6 20 Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheel front 6 39 Wheel rear 6 41 Wheels 6 22 U13S20E0 book Page 2 Thursday September 13 2007 2 14 PM ...

Page 108: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 109: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 110: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 09 0 3 1 CR E ...

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