Yamaha 2009 YZF-R6Y Owner'S Manual Download Page 81 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-29

7

EAU23142

Checking and lubricating the
brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.

EAU23202

Checking and 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

EWA10731

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.

Recommended lubricants:

Brake lever:

Silicone grease

Clutch lever:

Lithium-soap-based grease

Recommended lubricant:

Lithium-soap-based grease

U13S21E0.book Page 29 Tuesday, July 8, 2008 9:23 AM

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Summary of Contents for 2009 YZF-R6Y

Page 1: ...DIC183 YZF R6Y OWNER S MANUAL Read this manual carefully before operating this vehicle 13S 28199 21 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U13S21E0 book Page 1 Tuesday July 8 2008 9 23 AM ...

Page 3: ...y 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 dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur ren...

Page 4: ...bey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U13S21E0 book Page 1 ...

Page 5: ...MANUAL 2008 by Yamaha Motor Co Ltd 1st edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U13S21E0 book Page 2 Tuesday July 8 2008 9 23 AM ...

Page 6: ... 7 1 Periodic maintenance and lubrication chart 7 2 Removing and installing cowlings and panels 7 7 Checking the spark plugs 7 11 Engine oil and oil filter cartridge 7 12 Coolant 7 15 Air filter element 7 18 Checking the engine idling speed 7 18 Checking the throttle cable free play 7 19 Valve clearance 7 19 Tires 7 19 Cast wheels 7 22 Adjusting the clutch lever free play 7 22 Adjusting the rear b...

Page 7: ...ting the motorcycle 7 37 Front wheel 7 38 Rear wheel 7 40 Troubleshooting 7 41 Troubleshooting charts 7 43 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Motorcycle noise regulation for Australia 10 2 U13S21E0 book Page 2 Tuesday July 8 2008 9 23 AM ...

Page 8: ...vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 3 2 1 U13S21E0 book Page 1 Tuesday July 8 2008 9 23 AM ...

Page 9: ...LOCATION OF IMPORTANT LABELS 1 2 1 U13S21E0 book Page 2 Tuesday July 8 2008 9 23 AM ...

Page 10: ... passenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 whe...

Page 11: ...ld 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 Always wear protective clothing that covers your legs ankles and feet The en...

Page 12: ...s of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach an...

Page 13: ...eight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories ma...

Page 14: ... 6 Shock absorber assembly compression damping force adjusting bolt for slow compression damping page 4 24 7 Owner s tool kit page 7 1 8 Shock absorber assembly rebound damping force adjusting screw page 4 24 9 Shift pedal page 4 15 10 Engine oil filter cartridge page 7 12 11 Engine oil drain bolt page 7 12 12 Front fork compression damping force adjusting bolt for fast compres sion damping page 4...

Page 15: ...ry page 7 31 7 Air filter element page 7 18 8 Front brake fluid reservoir page 7 24 9 Radiator cap page 7 15 10 Coolant reservoir page 7 15 11 Engine oil filler cap page 7 12 12 Coolant drain bolt page 7 16 13 Engine oil dipstick page 7 12 14 Brake pedal page 4 16 15 Rear brake light switch page 7 23 16 Rear brake fluid reservoir page 7 24 U13S21E0 book Page 2 Tuesday July 8 2008 9 23 AM ...

Page 16: ... lever page 4 15 2 Left handlebar switches page 4 13 3 Main switch steering lock page 4 2 4 Multi function meter unit page 4 7 5 Right handlebar switches page 4 13 6 Brake lever page 4 15 7 Throttle grip page 7 19 U13S21E0 book Page 3 Tuesday July 8 2008 9 23 AM ...

Page 17: ...UR 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 a...

Page 18: ...e 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 TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems ar...

Page 19: ...the key in and then turn it to OFF while still pushing it 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 the key can be turned to NOTICE ECA11020 Do not use the parking position for an ...

Page 20: ... also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until 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 EAU11363 Fuel level warning light This warning light come...

Page 21: ...s warning light comes on if the en gine overheats If this occurs stop the engine immediately and allow the en gine 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 check the electrical cir cuit NOTICE ECA10021 Do not continue to operate the en gine if it is overheatin...

Page 22: ...h riding 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 7 43 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 43 TRIPA C TRIPA C TRIPA C TRIPA C U13S21E0 book Page 6 Tuesda...

Page 23: ...cator light and on how to set it EAU38621 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 the im m...

Page 24: ...s and shift timing indicator light 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 NOTICE ECA10031 Do not operate the engine in the ta chometer red zone...

Page 25: ...ll return 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 SELE...

Page 26: ... TIP Even if the air intake temperature is set to be displayed the coolant temperature warning light comes on if 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...

Page 27: ... both 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 NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as possibl...

Page 28: ...ss 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...

Page 29: ...to 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 ...

Page 30: ...he vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine 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 in th...

Page 31: ...m bination 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 han...

Page 32: ...p To 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 peda...

Page 33: ... of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ...

Page 34: ...3444 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10861 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the motorcycle in a place where pedestrians or children are not likely to touch the hot exhaust syste...

Page 35: ...he rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original po sition and then install the bolts Passenger seat To remove the passenger seat 1 Insert the key into the passenger seat lock and then turn it clock wise 1 Bolt 1 Projection 2 Seat holder U13S...

Page 36: ...seats are properly secured before riding EAU39073 Helmet holding cable A helmet holding cable is provided in the owner s tool kit to secure two hel mets to the helmet cable holder equipped on the bottom of the passen ger seat To secure a helmet with the helmet holding cable 1 Remove the passenger seat See page 4 19 2 Clip the middle snap hook of the cable onto the cable holder 1 Passenger seat loc...

Page 37: ...hen remove the cable from the helmet strap buck le 3 Install the passenger seat EAU38943 Adjusting the front fork WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws compres sion damping force adjusting bolts for fast compression dampin...

Page 38: ...force and thereby harden the rebound damp ing turn the adjusting screw on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in di rection b 1 Spring preload adjusting bolt 1 Current setting 2 Front fork collar Spring preload setting Minimum soft 0 Standard 2 Maximum hard 5 1 Rebound damping force adju...

Page 39: ...licks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary 1 Compression damping ...

Page 40: ...ection a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn...

Page 41: ...due to small differences in production WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Rebound damping setting Minimum soft 20 click s in direction b Standard 16 click s in direction b Maximum hard 3 click s i...

Page 42: ...ber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU38961 Luggage strap holders There are six luggage strap holders four on the bottom of the passenger seat and one on each passenger foot rest To use the luggage strap holders on the passenger seat remove the passenger seat unhook the straps from the hooks and then install the seat with the straps hanging o...

Page 43: ...tand or lower it with your foot while holding the vehicle upright TIP 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 EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not...

Page 44: ...mission is in 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 ...

Page 45: ... 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 not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch sw...

Page 46: ...ha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooli...

Page 47: ...ble free play and lubricate cable and grip housing 7 19 7 28 Control cables Make sure that operation is smooth Lubricate if necessary 7 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 25 7 27 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 19 7 22 Brake and shift pedals Make sure th...

Page 48: ... tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 27 ITEM CHECKS PAGE U13S21E0 book Page 3 Tuesday July 8 2008 9 23 AM ...

Page 49: ...ne from starting even though the engine will crank when pushing the start switch EAU26954 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sid estand up See page 4 28 for more informa tion 1 Turn the key to O...

Page 50: ...e than 10 seconds on any one at tempt EAU16671 Shifting 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 il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10260...

Page 51: ...d on 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 EAU17083 0 1000 km 0 600 mi Avoid prolonged operation above 8300 r min NOTICE After 1000 km 600 mi of operation the engine oil must be chang...

Page 52: ...nd exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U13S21E0 book Page 4 Tuesday July 8 2008 9 23 AM ...

Page 53: ...r with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to d...

Page 54: ... NO 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 ope...

Page 55: ...ck 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 Br...

Page 56: ...er 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 ...

Page 57: ... 30 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 s for looseness 34 Lights si...

Page 58: ... 6 7 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 U13S21E0 book Page 6 Tuesday July 8 2008 9 23 AM ...

Page 59: ...ed 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 U13S21E0 book Page 7 Tuesday July 8 2008 9 23 AM ...

Page 60: ...m 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 U13S21E0 book Page 8 Tuesday July 8 2008 9 23 AM ...

Page 61: ...s shown 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 7 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 signa...

Page 62: ... the 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...

Page 63: ...excessive 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 TIP If a torque wrench is not available when installing a spark plug a good estim...

Page 64: ...into the hole without screwing it in and then remove it again to check the oil level TIP 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 engine oil dipstick and then install and ...

Page 65: ...filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 9 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge TIP 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 S...

Page 66: ...l with the specified amount of the recommended engine oil and then install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE 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 67: ...rn 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 EAU39086 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TI...

Page 68: ...t frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Install the panel EAU39003 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove cowlings B and C See page 7 7 3 Place a contain...

Page 69: ... coolant into the reservoir to the maximum level mark and then install the coolant reservoir cap 14 Pour the recommended coolant into the radiator until it is full 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 1 Coolant drain bolt 2 Hose cla...

Page 70: ...ling system 18 Install the cowlings EAU36762 Air filter element The air filter element must be replaced at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the air filter element EAU44733 Checking the engine idling speed Check the engine idling speed and if necessary have it adjusted by a Yamaha dealer Engine idling speed 1250 1350 r min U13S21...

Page 71: ...art EAU21781 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10501 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air press...

Page 72: ...trol 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 TIP The tire tread depth limits may differ from country to country Always comply with the local regulations Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42...

Page 73: ...es Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately ...

Page 74: ...1 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...

Page 75: ...n a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals 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 in...

Page 76: ...he brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommend...

Page 77: ...lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22773 To check the dri...

Page 78: ...age To prevent this from occurring keep the drive chain slack with in the specified limits ECA10571 TIP Using the alignment marks on each chain puller make sure that both chain pullers are in the same position for proper wheel alignment Use the end of the swingarm as the reference point for the alignment marks 3 Tighten the axle nut to the speci fied torque 4 Tighten the adjusting bolts in direc t...

Page 79: ...11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11111 EAU23101 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each rid...

Page 80: ...n 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 U13S21E0 book Page 28 Tuesday July 8 2008 9 23 AM ...

Page 81: ...nd should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone...

Page 82: ...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 WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly...

Page 83: ...teering 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 there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU23444 Battery This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to ch...

Page 84: ...To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a con stant voltage battery charger have a Yamaha dealer charge your battery 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 pl...

Page 85: ...d 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 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 ...

Page 86: ...d 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 specified 1 Remove the headlight bulb cover by turning it counterclockwise 2 Disconnect the headlight coupler 3 Unhook the headlight bulb holder and then remove the burnt out...

Page 87: ... brake light This model is equipped with an LED type tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 1 Screw U13S21E0 book Page 35 Tuesday July 8 2008 9 23 AM ...

Page 88: ...plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing 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 1 Turn signal light bulb 1 Screw 1 License plate ligh...

Page 89: ...starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the 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 R...

Page 90: ...m the left side and then remove the wheel NOTICE Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut ECA11051 EAU33933 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the axle bolt and then lower the front wheel so that it is on the ground 4 Install the brake calipers by install ing th...

Page 91: ...the wheel axle 10 Tighten wheel axle pinch bolt D then pinch bolt C to the specified torque 11 Retighten pinch bolt D to the spec ified torque 12 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bolt 35 Nm 3 5 m kgf 25 ft lbf Tightening torque Axle bolt 91 Nm 9 1 m kgf 66 ft lbf 1 Front wheel axle pinch ...

Page 92: ... is difficult to re move remove the wheel axle first and then lift the wheel upward enough 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 NOTICE Do not apply the brake after the wheel has been re moved together with the brake disc otherwise the brake pads will be...

Page 93: ...rting 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 Imitation parts may look like ...

Page 94: ...ERIODIC MAINTENANCE AND ADJUSTMENT 7 42 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U13S21E0 book Page 42 Tuesday July 8 2008 9 23 AM ...

Page 95: ... 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 starter 4 Battery The engine turns over quickly The en...

Page 96: ...pped press down on the cap while turning it counterclockwise and then remove the cap TIP 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 l...

Page 97: ...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 drive chain and wheel axles Alway...

Page 98: ...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 during winter are extremely cor...

Page 99: ... 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 EWA11131 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac eto...

Page 100: ...t the 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 WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the...

Page 101: ...dge 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 3 5 L...

Page 102: ... Rear 290 kPa 2 90 kgf cm 42 psi 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 Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil sprin...

Page 103: ...dicator 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 15 0 A 2 Fuel injection system fuse 15 0 A Backup fuse 7 5 A Electronic thro...

Page 104: ...dentification 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 TIP The vehicle identification number is used to identify your motorcycle and may be used to register your ...

Page 105: ...OL SYSTEM 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 suc...

Page 106: ...adlight bulb replacing 7 34 Helmet holding cable 4 20 High beam indicator light 4 4 Horn switch 4 14 I Identification numbers 10 1 Ignition circuit cut off system 4 28 Immobilizer system 4 1 Immobilizer system indicator light 4 7 Indicator and warning lights 4 4 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 36 Luggage strap holders 4 26 M Main switch s...

Page 107: ... Troubleshooting charts 7 43 Turn signal indicator lights 4 4 Turn signal light bulb replacing 7 35 Turn signal switch 4 14 V Valve clearance 7 19 Vehicle identification number 10 1 W Wheel bearings checking 7 31 Wheel front 7 38 Wheel rear 7 40 Wheels 7 22 U13S21E0 book Page 2 Tuesday July 8 2008 9 23 AM ...

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 2008 07 0 3 1 CR E DIC183 ...

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