Yamaha Diver 510N XJ6SA Owner'S Manual Download Page 7 | Manualshive

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TABLE OF CONTENTS

Checking the front fork  .................6-33
Checking the steering ...................6-33
Checking the wheel bearings  .......6-34
Battery ..........................................6-34
Replacing the fuses  ......................6-35
Replacing the headlight bulb  ........6-37
Replacing the tail/brake light

bulb ...........................................6-38

Replacing a turn signal light

bulb ...........................................6-38

Replacing the license plate light

bulb ...........................................6-39

Auxiliary light bulb ........................6-40
Troubleshooting ............................6-40
Troubleshooting charts .................6-41

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

U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM

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Summary of Contents for Diver 510N XJ6SA

Page 1: ...DIC183 XJ6SA OWNER S MANUAL Read this manual carefully before operating this vehicle 36D 28199 E0 English E ...

Page 2: ...ER Hereby declare that the product Type designation 5SL 00 is in compliance with following norm s or documents R TTE Directive 1999 5 EC EN300 330 2 v1 3 1 2006 01 EN300 330 2 v1 5 1 2010 02 EN60950 1 2006 A11 2009 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC 1 2 3 4 Version up the norm of EN60950 to EN60950 1 To change company name version up of the following norm EN300 330 ...

Page 3: ...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 rent ...

Page 4: ...ential personal injury hazards Obey 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 ...

Page 5: ...ANUAL 2012 by Yamaha Motor Co Ltd 1st edition July 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U36DE0E0 book Page 2 Monday August 6 2012 5 14 PM ...

Page 6: ...ADJUSTMENT 6 1 Owner s tool kit 6 2 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 8 Checking the spark plugs 6 10 Engine oil and oil filter cartridge 6 11 Coolant 6 14 Replacing the air filter element 6 18 Adjusting the engine idling speed 6 19 Checking the throttle grip free play 6 20 Valv...

Page 7: ...g the tail brake light bulb 6 38 Replacing a turn signal light bulb 6 38 Replacing the license plate light bulb 6 39 Auxiliary light bulb 6 40 Troubleshooting 6 40 Troubleshooting charts 6 41 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 U36DE0E0 book Page 2 Monday August 6 2012 5 14 PM ...

Page 8: ...you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to car ry the operator and a passenger The failure of motorists to detect and recogni...

Page 9: ...to main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is no...

Page 10: ...cle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo ...

Page 11: ...ange any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle 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 ...

Page 12: ...uc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the mot...

Page 13: ...djusting screw page 6 19 3 Seat lock page 3 18 4 Main fuse page 6 35 5 Fuse box page 6 35 6 Owner s tool kit page 6 2 7 Storage compartment page 3 19 8 Shift pedal page 3 13 9 Engine oil filter cartridge page 6 11 10 Engine oil drain bolt page 6 11 U36DE0E0 book Page 1 Monday August 6 2012 5 14 PM ...

Page 14: ...page 6 26 4 Engine oil filler cap page 6 11 5 Radiator cap page 6 14 6 Coolant reservoir page 6 14 7 Coolant drain bolt page 6 15 8 Engine oil dipstick page 6 11 9 Brake pedal page 3 14 10 Rear brake light switch page 6 25 11 Shock absorber assembly spring preload adjusting ring page 3 20 U36DE0E0 book Page 2 Monday August 6 2012 5 14 PM ...

Page 15: ... 13 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Front brake fluid reservoir page 6 26 6 Right handlebar switches page 3 11 7 Throttle grip page 6 20 8 Brake lever page 3 13 U36DE0E0 book Page 3 Monday August 6 2012 5 14 PM ...

Page 16: ...MEDIATELY 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 keep the ...

Page 17: ...fe 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 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 e...

Page 18: ...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 exte...

Page 19: ...s is not a malfunction This model is 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 EAU1142A Coolant temp...

Page 20: ... en gine if it is overheating TIP For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 42 for further instructions U36DE0E0 book Page 5 Monday August 6 2012 5 14 PM ...

Page 21: ...ad with riding 117 134 C 243 274 F Coolant temperature 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 42 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 ABS ABS U36DE0E0 book Page 6 Monday August 6 2012 5 1...

Page 22: ...ng light does not go off after traveling at a speed of 10 km h 6 mi h or higher or if the warning light comes on or flashes while riding the brake system re verts to conventional braking If ei ther of the above occurs or if the warning light does not come on at all use extra caution to avoid possi ble wheel lock during emergency braking Have a Yamaha dealer check the brake system and electri cal c...

Page 23: ...o turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second 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 swee...

Page 24: ...nd TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 2 L 0 85 US gal 0 70 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the displ...

Page 25: ...uit Coolant temperature display The coolant temperature display indi cates the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the displa...

Page 26: ...er key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or 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 register...

Page 27: ...overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU42341 The engine trouble warning light and ABS warning light may come on when the key is turned to ON and the start switch is pushed but this does not indi cate a malfunction EAU12733 Hazard switch With th...

Page 28: ...en shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU26824 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever toward the throttle grip The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip turn the ad justing...

Page 29: ...ce may be longer with the ABS than without The ABS is monitored by an ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a clicking noise can be heard from under the seat ...

Page 30: ...ush 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 TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11091 Make sure that the fuel tank cap is properly closed after filli...

Page 31: ...r plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water If gaso li...

Page 32: ...tem 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 vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a fe...

Page 33: ...ey TIP Make sure that the seat is properly se cured before riding EAU46751 Helmet holder The helmet holder is located under the seat A helmet holding cable is provid ed in the owner s tool kit to secure a helmet to the helmet holder To secure a helmet to the helmet holder 1 Remove the seat See page 3 18 2 Pass the helmet holding cable through the buckle on the helmet strap as shown and then hook t...

Page 34: ...ll the seat EAU14453 Storage compartment The storage compartment is located under the seat See page 3 18 When storing the Owner s Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb fo...

Page 35: ...is shock absorber assembly is equipped with a spring preload adjust ing ring NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Adjust the spring preload as follows 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 t...

Page 36: ... frame Raise the sidestand 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 the following section for an expla nation of the ignition circuit cut off sys tem WARNING EWA10241 The vehicle must not be ridden with the sidestand down or if the side stand cannot...

Page 37: ...unctions It prevents starting when the trans 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 sidestand is moved down Periodically check the operation of the ignition circuit cut off ...

Page 38: ... clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be ...

Page 39: ...oints ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or dam age and check hose connections 3 16 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 Coolant Check coolant level in reservoir If necess...

Page 40: ...rip free play and lubricate cable and grip housing 6 20 6 30 Control cables Make sure that operation is smooth Lubricate if necessary 6 30 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 28 6 29 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 20 6 23 Brake and shift pedals Make sure th...

Page 41: ... 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 3 21 ITEM CHECKS PAGE U36DE0E0 book Page 3 Monday August 6 2012 5 14 PM ...

Page 42: ...tically if left idling for 20 minutes In this case the multi function meter unit indi cates error code 70 but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU54581 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 tra...

Page 43: ...rt the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one at tempt NOTICE ECA11042 For maximum engine life never ac celerate hard when the engine is cold EAU16671 Shifting Shifting gears le...

Page 44: ...th no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new ...

Page 45: ...cle EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and 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...

Page 46: ...n 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 death See page 1 3 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers ...

Page 47: ...n 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 wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit 1 U36DE0E0 book Page 2 Monday August ...

Page 48: ...0 Periodic maintenance chart for the emission control system 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 Fuel injection Adjust ...

Page 49: ...r fluid leakage Replace brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 6 Brake fluid Replace Every 2 years 7 Wheels Check runout and for damage 8 Tires Check tread depth and for dam age Repl...

Page 50: ...ase Every 20000 km 12000 mi 13 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Shift pedal pivot shaft Lubricate with lithium soap based grease 18 Sidestand center stan...

Page 51: ...cle for coolant leakage Change coolant Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 6...

Page 52: ...ir filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level 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 U36DE0E0 book Page 7 Monday A...

Page 53: ... be re moved and installed EAU46770 Panel A To remove the panel Remove the bolt and the quick fasten er and then take the panel off To install the panel Place the panel in the original position and then install the bolt and the quick fastener EAU47881 Panels B and C To remove a panel 1 Remove the bolts 1 Cowling A 2 Cowling B 1 2 1 Panel A 2 Cowling C 1 Panel B 2 Panel C 2 1 2 1 1 Panel A 2 Bolt 3...

Page 54: ...remove the cowling Remove the bolts and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU47582 Cowlings B and C To remove a cowling 1 Remove panel B if removing cowl ing B or panel C if removing cowl ing C 2 Remove the quick fastener and the bolts and then take the cowl ing off 1 Panel B 2 Bolt 1 Projection 2 1 1 1 Cowling A...

Page 55: ...cation chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be o...

Page 56: ...be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes u...

Page 57: ...e 6 8 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil dipstick ...

Page 58: ... 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 fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial...

Page 59: ...t 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 EAU47560 To check the coolant level 1 Place the vehicle on the center stand TIP The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when ch...

Page 60: ...content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Route the coolant reservoir breath er hose through the guide as shown EAU47573 To change the coolant 1 Place the vehicle on the center stand 2 Remove cowlings A and C See page 6 8 3 Place a container under the engine to collect the used coolant 4 Remove the radiator cap retaining bolt r...

Page 61: ...sh the cool ing system with clean tap water 10 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 11 Install the coolant reservoir and its cover by placing them in the origi nal position and then installing the bolts 12 Pour the specified amount of the recommended coolant into the ra diator and reservoir 1 Coolant reservoir cap 2 Coolant reservoir b...

Page 62: ...d then install the cap 18 Route the coolant reservoir breath er hose through the guide as shown 19 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 20 Install the cowlings Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum ...

Page 63: ...ke sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10481 7 Install the air filter case cover by in stalling the screws 8 Place the fuel tank in its original position Make sure that the fuel hoses are properly connected and r...

Page 64: ...chart The engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer ma...

Page 65: ...ly contact between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10503 Opera...

Page 66: ... 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 to do so Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire air pre...

Page 67: ... only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tir...

Page 68: ...eel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life EAU47590 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 ...

Page 69: ...play turn the adjusting nut in direction b 5 Tighten the locknut 6 Install the cowling EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14211 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydrauli...

Page 70: ...hecking 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 EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator gr...

Page 71: ...e pads as a set EAU43112 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if necessary Front brake Rear brake TIP The rear brake fluid reservoir is located behind panel A See page 6 8 WARNING EWA16010 Improper maintenance can result in loss of braking abi...

Page 72: ...ts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads and or brake sys tem leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EA...

Page 73: ...ace the motorcycle on the cen terstand 4 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can le...

Page 74: ...vice the drive chain as follows NOTICE ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughl...

Page 75: ...place damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU49920 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart EAU44273 Checking and lubricating the brake and shift pedals Th...

Page 76: ...brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U36DE0E0 book Page 31 Monday August 6 2012 5 14 PM ...

Page 77: ...es not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control EAUM1652 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubric...

Page 78: ...s several times to check if the front fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU45511 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintena...

Page 79: ...s sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries...

Page 80: ...l be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure the key is turned to OFF then con nect the positive lead before connecting the negative lead ECA16840 4 After installation make sure that the battery leads are properly con nected to the battery terminals NO...

Page 81: ...es 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Taillight fuse 2 ABS control unit fuse 3 ABS solenoid fuse 4 ABS motor fuse 5 Spare fuse 6 Headlight fuse 7 Ignition fuse 8 Signaling system fuse 9 Backup fuse for clock and immobilizer sys tem 10 Fuel injection system fuse 11 Radiator fan fuse 1 5 5 6 7 8 9 10 11 2 34 Specified fuses Main fuse 30 0 A Headl...

Page 82: ...hol 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 cowling B See page 6 8 2 Disconnect the headlight coupler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the burnt out bulb 4 Place a new headlight bulb into po sition and then secur...

Page 83: ...a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the seat 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 Tail brake light bulb socket 1 1 Tail brake light bulb 2 Tail brake light bulb socket 2 1 1 Turn signal ...

Page 84: ...se plate light unit by removing the screws 2 Remove the license plate light bulb 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 1 License plate light unit 2 Screw 2...

Page 85: ...e 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 Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNI...

Page 86: ... Have a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The engine does not st...

Page 87: ... hissing sound has stopped 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 th...

Page 88: ...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 89: ...onge 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 corrosive in combination with water car...

Page 90: ... 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 etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the mot...

Page 91: ...e spark plugs and then place the spark plugs on the cylinder head so that 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...

Page 92: ...MOTORCYCLE CARE AND STORAGE 7 5 7 TIP Make any necessary repairs before storing the motorcycle U36DE0E0 book Page 5 Monday August 6 2012 5 14 PM ...

Page 93: ...0 Imp qt With oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 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 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 17 3 L 4 57 US gal 3 81 Im...

Page 94: ... 50 kgf cm 36 psi Loading condition 90 184 kg 198 406 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 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 MT4 50 Front brake Type Dual disc brake Operation Right hand operation Specified brake ...

Page 95: ...ghting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan fuse 20 0 ...

Page 96: ...ation 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 motorcy cle with the licensing authority in your area EAU26480 Model label The model label is affixed to the frame under the seat See page 3 18 Record the information on this label in the space provi...

Page 97: ...rflow hose 3 17 Fuel tank cap 3 15 Fuses replacing 6 35 H Handlebar position adjusting 3 20 Handlebar switches 3 11 Hazard switch 3 12 Headlight bulb replacing 6 37 Helmet holder 3 18 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator lights and warning lights 3 4 L...

Page 98: ...ooting charts 6 41 Turn signal indicator light 3 4 Turn signal light bulb replacing 6 38 Turn signal switch 3 12 V Valve clearance 6 20 Vehicle identification number 9 1 W Wheel bearings checking 6 34 Wheels 6 23 U36DE0E0 book Page 2 Monday August 6 2012 5 14 PM ...

Page 99: ...U36DE0E0 book Page 3 Monday August 6 2012 5 14 PM ...

Page 100: ...PRINTED IN JAPAN 2012 08 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER ...

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