Yamaha DIVERSION XJ6S 2012 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-19

6

the engine, otherwise fuel may
leak, creating a fire hazard.

[EWA12463]

9. Install the fuel tank bolts.

10. Install the panels.
11. Install the seat.

EAU34301

Adjusting the engine idling
speed

The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
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 make the adjustment.

1. Hose

1. Original position (paint mark)

1

1

1. Idle adjusting screw

1

(a)

(b)

Engine idling speed:

1250–1350 r/min

U36CE3E0.book Page 19 Wednesday, May 30, 2012 11:51 AM

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Summary of Contents for DIVERSION XJ6S 2012

Page 1: ...DIC183 XJ6S OWNER S MANUAL Read this manual carefully before operating this vehicle 36C 28199 E3 English E ...

Page 2: ...R 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 2...

Page 3: ... 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 pr...

Page 4: ...ntial 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 N...

Page 5: ...NUAL 2012 by Yamaha Motor Co Ltd 1st edition May 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U36CE3E0 book Page 2 Wednesday May 30 2012 11 51 AM ...

Page 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 Valve clearance 6 20 Tires 6 20 Cast w...

Page 7: ...urn signal light bulb 6 38 Replacing the license plate light bulb 6 39 Auxiliary light bulb 6 39 Front wheel 6 40 Rear wheel 6 41 Troubleshooting 6 42 Troubleshooting charts 6 44 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U36CE3E0 book Page 2 Wednesday May 30 2012 11 51 AM ...

Page 8: ...ou 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 recogniz...

Page 9: ...o 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 not...

Page 10: ...le 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 m...

Page 11: ...nge 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 f...

Page 12: ...c 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 moto...

Page 13: ...justing screw page 6 19 3 Seat lock page 3 16 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 18 8 Shift pedal page 3 13 9 Engine oil filter cartridge page 6 11 10 Engine oil drain bolt page 6 11 U36CE3E0 book Page 1 Wednesday May 30 2012 11 51 AM ...

Page 14: ...age 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 13 10 Rear brake light switch page 6 25 11 Shock absorber assembly spring preload adjusting ring page 3 19 U36CE3E0 book Page 2 Wednesday May 30 2012 11 51 AM ...

Page 15: ...12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 7 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 U36CE3E0 book Page 3 Wednesday May 30 2012 11 51 AM ...

Page 16: ...EDIATELY 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 c...

Page 17: ...e 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 el...

Page 18: ...ey 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 exten...

Page 19: ...lfunction 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 temperature warni...

Page 20: ...adiator 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 45 for further instructions U36CE3E0 book Page 5 Wednesday May 30 2012 11 51 AM ...

Page 21: ...ahead 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 45 Above 134 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 45 U36CE3E0 book Page 6 Wednesday May 30 2012 11 51 A...

Page 22: ... If the indicator light does not come on initially when the key is turned to ON or if the indicator light remains on have a Yamaha dealer check the electrical circuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer...

Page 23: ...he 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 Red zone 11666 r min and above Clock The clock displays when the key is turned to ON In ad...

Page 24: ...IP To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display seg ments of the fue...

Page 25: ...stem circuits the immobilizer system indicator light will flash and the display will indicate an error code TIP If the display indicates error code 52 this could be caused by transponder in terference If this error code appears try the following 1 Use the code re registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more tha...

Page 26: ...eft Right EAU12350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard...

Page 27: ... a malfunction EAU12733 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard NOTICE ECA10061 Do not use the hazard lights for an extended length of time with the en gine...

Page 28: ... equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip turn the ad justing dial while holding the lever pushed away from the throttle grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the ...

Page 29: ... fuel is a fire hazard EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi c...

Page 30: ... as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU51190 Fuel tank breather hose and overflow ...

Page 31: ...ust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU32980 Seat To remove the seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While ...

Page 32: ...e helmet strap as shown and then hook the cable loops over the helmet hold er 3 Place the helmet on the right side of the vehicle and then install the seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident EWA10161 To release the helmet from the hel met holder Remove the seat remove the helmet holding ca...

Page 33: ...ng 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 for the storage com partment Do not exceed the maximum load of 189 kg 417 lb for the ve hicle EAU46831 Handlebar position The handlebar can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handleba...

Page 34: ...load 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 in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and exten sion bar included in the owner s tool kit to make the adjustment WARNING EWA10221 ...

Page 35: ...hile 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 be properly moved up or does not stay up otherwise the...

Page 36: ...ission 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 system according to the following procedure U3...

Page 37: ...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 w...

Page 38: ...ints 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 14 3 15 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 necessa...

Page 39: ...ip 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 tha...

Page 40: ...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 20 ITEM CHECKS PAGE U36CE3E0 book Page 3 Wednesday May 30 2012 11 51 AM ...

Page 41: ...cally 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 EAU3935B 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 trans...

Page 42: ...fting 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 Even with the transmission in the neutral position do not ...

Page 43: ...fully Since the engine is brand new do not put an excessive load 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 EAU17093 0 1000 km 0 600 mi Avoid prolonged operation above 5800 r min NOTICE...

Page 44: ...d 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 U36CE3E0 book Page 4 Wednesday May 30 2012 11 51 AM ...

Page 45: ... 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 d...

Page 46: ... 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 U36CE3E0 book Page 2 Wednesday May 3...

Page 47: ... 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 e...

Page 48: ...el and vehicle for 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 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Ch...

Page 49: ...se Every 20000 km 12000 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand center stand...

Page 50: ...le for coolant leakage Change coolant Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 60...

Page 51: ...r 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 U36CE3E0 book Page 7 Wednesday...

Page 52: ...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 53: ...emove 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 54: ...ation 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 op...

Page 55: ...e 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 un...

Page 56: ... 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 2...

Page 57: ...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 58: ... 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 che...

Page 59: ...ontent 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 ra...

Page 60: ...h 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 br...

Page 61: ... 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 e...

Page 62: ...e 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 ro...

Page 63: ...hart 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 mak...

Page 64: ...y 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 Operat...

Page 65: ...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 pres...

Page 66: ...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 tire...

Page 67: ...el 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 1...

Page 68: ...lay 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 hydraulic...

Page 69: ... the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22392 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 EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to c...

Page 70: ... pads as a set EAU39372 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 EWA15990 Improper maintenance can result in loss of braking abil...

Page 71: ...diately 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 EAU22731 Changing the brake fluid Have ...

Page 72: ...ce 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 lea...

Page 73: ...ice 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 Thoroughly...

Page 74: ...lace 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 The...

Page 75: ...rake 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 U36CE3E0 book Page 31 Wednesday May 30 2012 11 51 AM ...

Page 76: ...s 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 lubrica...

Page 77: ... 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 maintenan...

Page 78: ... 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 79: ... 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 NOT...

Page 80: ...o damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb 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 ...

Page 81: ...hen connect the coupler 6 Install the cowling 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU47021 Replacing the tail brake light bulb 1 Remove the seat See page 3 16 2 Remove the tail brake light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pull ing it out 1 Do not touch the glass part of the bulb 1 Headlight bulb cover 2 Headl...

Page 82: ...rew 2 Remove the burnt out 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 NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 1 Tail brake light bulb 2 Tail brake light bulb socket 2 1 1 Turn signal light lens 2 Screw 1 2 1 Turn signal ...

Page 83: ...t 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 EAU39020 Auxiliary light bulb If the auxiliary light does not come on have a Yamaha dealer check the elec trical circuit or replace the bulb 1 License plate light unit 2 Screw 2 1 1 License plate light bulb socket 2 License plate light b...

Page 84: ... fork legs 2 Insert the wheel axle 3 Install the brake calipers by install ing the bolts TIP Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Take the motorcycle off the center stand so that the front wheel is on the ground and then put the side stand down 5 Tighten the wheel axle the front wheel axle pinch bolt and the brake ...

Page 85: ... not need to be disassembled in order to remove and install the rear wheel 6 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out TIP A rubber mallet may be useful to tap the wheel axle out 7 Remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU486...

Page 86: ...el compression or ignition systems 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...

Page 87: ...IODIC MAINTENANCE AND ADJUSTMENT 6 43 6 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U36CE3E0 book Page 43 Wednesday May 30 2012 11 51 AM ...

Page 88: ...er 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 engine turns o...

Page 89: ...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 the...

Page 90: ...utlet 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 Always...

Page 91: ...ild 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 corros...

Page 92: ...x to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26182 Sto...

Page 93: ...the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively tu...

Page 94: ... 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 Imp...

Page 95: ...50 kgf cm 36 psi Loading condition 90 189 kg 198 417 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 f...

Page 96: ...0 W 1 License plate light 12 V 5 0 W 1 Meter lighting 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 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 ...

Page 97: ...tion 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 16 Record the information on this label in the space provid...

Page 98: ...s replacing 6 35 H Handlebar position adjusting 3 18 Handlebar switches 3 11 Hazard switch 3 12 Headlight bulb replacing 6 36 Helmet holder 3 17 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 21 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator lights and warning lights 3 4 L License plate light bulb replacing 6 3...

Page 99: ... light 3 4 Turn signal light bulb replacing 6 38 Turn signal switch 3 11 V Valve clearance 6 20 Vehicle identification number 9 1 W Wheel bearings checking 6 34 Wheel front 6 40 Wheel rear 6 41 Wheels 6 23 U36CE3E0 book Page 2 Wednesday May 30 2012 11 51 AM ...

Page 100: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 101: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 102: ...PRINTED IN JAPAN 2012 06 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER ...

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