Yamaha FJR 2005 Owner'S Manual Download Page 74 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

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.

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 groove. If a brake
pad has worn to the point that the wear

indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22500

Rear brake pads

Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.

EAU40270

Checking the brake and clutch
fluid levels

Front brake

Rear brake

1. Brake pad wear indicator groove

1. Lining thickness

1. Minimum level mark

1. Minimum level mark

U3P620E0.book Page 21 Tuesday, January 24, 2006 10:47 AM

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Summary of Contents for FJR 2005

Page 1: ...3P6 28199 20 FJR1300AV OWNER S MANUAL ProCarManuals com ...

Page 2: ...U3P620E0 book Page 2 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 3: ...ll advantages of your FJR1300AV The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Y...

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

Page 5: ...by Yamaha Motor Co Ltd 1st edition December 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U3P620E0 book Page 2 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 6: ... operation check list 4 2 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting the engine 5 1 Shifting 5 2 Tips for reducing fuel consumption 5 3 Engine break in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing panels 6 5 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Final gear...

Page 7: ...signal light 6 32 Replacing a rear turn signal light bulb or a tail brake light bulb 6 32 Replacing the license plate light bulb 6 33 Replacing an auxiliary light bulb 6 33 Troubleshooting 6 34 Troubleshooting charts 6 35 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U3P620E0...

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

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

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

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

Page 12: ...NFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3P620E0 book Page 5 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 13: ...e this vehicle read the owner s manual Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 U3P620E0 book Page 6 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 14: ...e 3 17 6 Passenger seat page 3 17 7 Final gear oil filler bolt page 6 12 8 Final gear oil drain bolt page 6 12 9 Shock absorber assembly spring preload adjusting lever page 3 25 10 Air filter element page 6 15 11 Shift pedal page 3 13 12 Engine oil filler cap page 6 9 13 Engine oil filter cartridge page 6 9 14 Engine oil level check window page 6 9 U3P620E0 book Page 1 Tuesday January 24 2006 10 4...

Page 15: ...ld page 3 11 5 Battery page 6 28 6 Main fuse page 6 29 7 Front fork compression damping force adjusting screw page 3 24 8 Brake pedal page 3 14 9 Shock absorber assembly rebound damping force adjusting knob page 3 25 10 Rear brake fluid reservoir page 6 21 U3P620E0 book Page 2 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 16: ...age 6 21 5 Tachometer page 3 5 6 Speedometer page 3 5 7 Multi function display page 3 6 8 Front brake fluid reservoir page 6 21 9 Right handlebar switches page 3 11 10 Brake lever page 3 14 11 Throttle grip page 6 17 12 Main switch steering lock page 3 2 13 Headlight beam adjusting knob page 3 22 U3P620E0 book Page 3 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 17: ... 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 code re regis tering key i...

Page 18: ...ting taillights li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF EAU10660 OFF All electrical systems are off The key can be removed EAU10690 LOCK The steering is locked and all electrical systems are off The key can be re moved To...

Page 19: ...ut all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed...

Page 20: ...then go off have a Yamaha dealer check the electrical circuit EAU39500 ABS warning light If this warning light comes on or flashes while riding the ABS may be defective If this occurs have a Yamaha dealer check the system as soon as possible See page 3 14 WARNING EWA10081 If the ABS warning light comes on or flashes while riding the brake sys tem reverts to conventional braking Therefore be carefu...

Page 21: ...t the electrical cir cuit EAU11872 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 90...

Page 22: ...neous and average consumption functions a self diagnosis device NOTE Be sure to turn the key to ON before using the SELECT and RESET but tons Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO NOTE When selecting TRIP 1 or TRIP 2 the display flashes for five...

Page 23: ...nd the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display seg ments of the fuel meter disappear to wards E Empty as the fuel level decreases When the last segment starts flashing refuel as soon as possi ble When the key is tur...

Page 24: ...ion gear display This display shows the selected gear The neutral position however is not displayed it is indicated by the neutral indicator light Ambient temperature instanta neous fuel consumption and aver age fuel consumption modes Push the RESET button to switch the display between the ambient tempera ture mode Air the instantaneous fuel consumption mode km L or L 100 km and the average fuel c...

Page 25: ...ion mode The instantaneous fuel consumption display can be set to either km L or L 100 km When the display is set to km L the distance that can be traveled on 1 0 L of fuel under the current riding conditions is shown When the display is set to L 100 km the amount of fuel necessary to travel 100 km under the current riding conditions is shown NOTE To switch between the two instan taneous fuel cons...

Page 26: ...evice for various electrical cir cuits If any of those circuits are defective the multi function display will indicate a two digit error code e g 11 12 13 If the multi function display indicates such an error code note the code num ber and then have a Yamaha dealer check the vehicle CAUTION ECA11790 If the multi function display indi cates an error code the vehicle should be checked as soon as pos...

Page 27: ...ates any error codes note the code number and then have a Yamaha dealer check the vehicle EAU12344 Handlebar switches Left Right EAU12380 Pass switch Press this switch to flash the head lights 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 ...

Page 28: ...n emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine 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 T...

Page 29: ...r pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the clutch lever The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 28 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever whe...

Page 30: ...pply both the brake le ver and the brake pedal simultaneous ly EAU39530 ABS The Yamaha ABS Anti lock Brake System features a dual electronic con trol system which acts on the front and rear brakes independently The ABS is monitored by an ECU Electronic Con trol Unit which will have recourse to manual braking if a malfunction occurs WARNING EWA10090 The ABS performs best on long braking distances O...

Page 31: ...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 NOTE 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 pro...

Page 32: ... EAU13330 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unle...

Page 33: ...er materials that easily burn Do not allow the engine to idle too long EAU39491 Seats Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 Lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projections on the rear of the passenger seat into the seat holders as shown and then push the fro...

Page 34: ...iding posi tion See page 3 18 EAU39632 Adjusting the rider seat height The rider seat height can be adjusted to one of two positions to suit the rider s preference The rider seat height was adjusted to the lower position at delivery To change the rider seat height to the high position 1 Remove the rider seat See page 3 17 2 Remove the rider seat height posi tion adjuster by pulling it upward 1 Rid...

Page 35: ...wn 7 Install the passenger seat To change the rider seat height to the low position 1 Remove the rider seat See page 3 17 2 Remove the rider seat height posi tion adjuster by pulling it upward 3 Move the rider seat holder cover to the upper position 4 Install the rider seat height position adjuster so that the L mark is aligned with the match mark 1 Rider seat height position adjuster 1 Rider seat...

Page 36: ...t the seats are properly secured before riding EAU40250 Storage compartments This vehicle is equipped with two stor age compartments Storage compartment A is located un der the rider seat See page 3 17 Storage compartment B is located un der the passenger seat See page 3 17 1 Rider seat height position adjuster 2 L mark 3 Match mark 1 Projection 2 Seat holder A for low position 3 Rider seat holder...

Page 37: ... the accessory box button and then open the accessory box lid 3 Turn the key to OFF to preserve the battery To close the accessory box 1 Fold the accessory box lid down 2 Remove the key CAUTION ECA11800 Do not place heat sensitive items in the accessory box The accessory box gets extremely hot especially when the engine is running or is hot WARNING EWA11421 Do not exceed the load limit of 0 3 kg 0...

Page 38: ...ms turn the knobs in direction a To lower the headlight beams turn the knobs in di rection b EAU39641 Handlebar position The handlebars can be adjusted to one of three positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handlebars EAU39621 Opening and closing the cowlings The cowlings can be tilted back 30 mm 1 18 in for added ventilation to suit the riding co...

Page 39: ...y installed before riding EAU39671 Rear view mirrors The rear view mirrors of this vehicle can be folded forward or backward for park ing in narrow spaces Fold the mirrors back to their original position before riding WARNING EWA14371 Be sure to fold the rear view mirrors back to their original position before riding 1 Quick fastener screw 1 Open position 1 Quick fastener screw 1 Closed position 1...

Page 40: ...appropriate groove on the ad justing mechanism with the top of the front fork cap bolt Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting knob on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob on each fork leg in direc tion b 1 Spring preload adjust...

Page 41: ...s 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 EAU14911 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing lever and a rebound damping force adjusting knob CAUTION EC...

Page 42: ...fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as ...

Page 43: ...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 stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of...

Page 44: ...rting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed on the centerstand during this in spection If a ma...

Page 45: ...ne has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not b...

Page 46: ...ned off and the load must never exceed 30 W 2 5 A otherwise the battery may dis charge To use the auxiliary DC jack 1 Open the accessory box lid See page 3 21 2 Turn the key to OFF 3 Remove the auxiliary DC jack cap 4 Insert the accessory plug into the auxiliary DC jack 5 Turn the key to ON and then start the engine See page 5 1 WARNING EWA14360 To prevent electrical shock or short circuiting make...

Page 47: ...erefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not working pro...

Page 48: ...aulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 21 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake flui...

Page 49: ...ooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches C...

Page 50: ...EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 28 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15450 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light Engine tro...

Page 51: ...sition press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the tr...

Page 52: ...e 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 EAU17121 0 1000 km 0 600 mi Avoid prolonged operation above 4500 r min 1000 1600 km 600 1000 mi Av...

Page 53: ...nd exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U3P620E0 book Page 4 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 54: ...iliar with mainte nance work have a Yamaha dealer do it for you EAU17360 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 17 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be n...

Page 55: ...0 km ANNUAL CHECK 1 10 20 30 40 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 4 Air filter element Clean Replace 5 Clutch Check operation fluid level and vehicle for fluid leakage 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to t...

Page 56: ...l nuts bolts and screws are properly tightened 15 Sidestand centerstand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Shock absorber assem bly Check operation and shock absorber for oil leakage 19 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based grease 20 Fuel injectio...

Page 57: ...or damaged 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip ...

Page 58: ...e the bolts 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 bolts and the quick fastener EAU39562 Panel B To remove the panel 1 Open the accessory box lid See page 3 21 2 Remove the bolt screw and the quick fasteners shown and then take the panel off 1 Panel A 2 Panel B 3 Panel C 4 Panel D 1 Panel E 1 Panel F 1 ...

Page 59: ... ECA15420 Do not remove the headlight beam adjusting cable To install the panel 1 Place the panel in the original posi tion and then install the bolt and quick fastener 2 Install the panel EAU39582 Panel D To remove the panel 1 Remove panels B and C See page 6 5 2 Remove the bolts and quick fas tener shown and then remove the panel 1 Panel B 2 Bolt 3 Screw 4 Quick fastener 1 Panel C 2 Bolt 3 Quick...

Page 60: ...E To remove the panel 1 Remove the seats See page 3 17 2 Remove the bolts and the quick fastener screws and then take the panel off To install the panel 1 Place the panel in the original posi tion and then install the bolts and the quick fastener screws 2 Install the seats 1 Panel D 2 Bolt 3 Quick fastener 1 Headlight beam adjusting cable 1 Panel D 1 Panel E 2 Bolt 3 Quick fastener screw U3P620E0 ...

Page 61: ...cordance with the periodic mainte nance and lubrication 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...

Page 62: ... 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 NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm ...

Page 63: ...ollect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1 Engine oil level check ...

Page 64: ... than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oi...

Page 65: ... the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on the center stand NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the oil filler bolt and then check the oil leve...

Page 66: ...eck the coolant level The coolant level should be checked as follows before each ride In addition the coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart 1 Place the vehicle on the center stand NOTE 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 u...

Page 67: ...ngine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fans ar...

Page 68: ...iodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove panel E See page 6 5 2 Remove the intake air shroud by removing the screw and the quick fastener screws 3 Remove the air filter case cover by removing the screws 4 Pull the air filter element out 5 Lightly tap the air filter element to remove most of the ...

Page 69: ...ure that the fuel tank breath er overflow hose is not pinched 8 Install the intake air shroud by in stalling the screw and the quick fastener screws 9 Install the panel EAU21310 Checking the engine idling speed The engine idling speed must be checked as follows and if necessary adjusted by a Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication chart Start the engi...

Page 70: ... the periodic maintenance and lubrication chart EAU21780 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 EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temper...

Page 71: ...ead depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related ...

Page 72: ...h speed tires 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 app...

Page 73: ...t be broken in for it to develop its optimal characteris tics EAU22072 Clutch lever Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride If the clutch lever free play does become excessive and shifting becomes rough or clutch slippa...

Page 74: ... wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 0 8 mm 0 03 in have a Yamaha dealer replace the brake pads as a set EAU...

Page 75: ...of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance The brake or clutch fluid reservoir diaphragm will lose its shape from the negative pressure if the fluid level goes down too far Be sure to return the diaphragm to its original shape before installing it into the brake or clutch fluid reservoir Be careful that water or dust does ...

Page 76: ...of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soo...

Page 77: ...vots should be lu bricated if necessary EAU23140 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 Recommended lubricant Lithium soap based grease all pur pose grease U3P620E0 book Page 24 Tuesday January 24 2006 10 47 AM ProCarManuals ...

Page 78: ...tand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Recommended...

Page 79: ...NG EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly CAUTI...

Page 80: ...he vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is...

Page 81: ... EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than one month remove th...

Page 82: ...key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Fuse box 3 ABS motor fuse 4 ABS motor spare fuse 1 Fuse box 2 Right radiator fan fuse 3 Left radiator fan fuse 4 Hazard fuse 5 Backup fuse for odometer clock and immo bilizer system 6 Headlight fuse 7 Signaling system fuse 8 ABS control unit fuse 9 ...

Page 83: ...lb burns out replace it as follows 1 Remove panel D if replacing the left headlight bulb or panel C if re placing the right headlight bulb See page 6 5 2 Disconnect the headlight coupler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb Specified fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0...

Page 84: ...par ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Install the headlight bulb cover an...

Page 85: ...seat See page 3 17 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat 1 Turn signal light bulb socket 2 Tail br...

Page 86: ...alling the screws EAU27011 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove panel D if replacing the left auxiliary light bulb or panel C if replacing the right auxiliary light bulb See page 6 5 2 Remove the auxiliary light socket together with the bulb by turning the socket counterclockwise 3 Re...

Page 87: ...r starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look ...

Page 88: ...Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine ...

Page 89: ...und has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling ...

Page 90: ...leaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Be sure to...

Page 91: ...eaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel pl...

Page 92: ...s chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place...

Page 93: ...order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see pa...

Page 94: ...aft drive gear oil Quantity 0 20 L 0 21 US qt 0 18 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 60 L 2 75 US qt 2 29 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 25 0 L 6 61 US gal 5 50 Imp gal Fuel reserve amount 5 5 L 1 45 US ...

Page 95: ...0 kPa 42 psi 2 90 kgf cm High speed riding Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 ...

Page 96: ...ED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS control unit fuse 10 0 A ABS motor...

Page 97: ... number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle ...

Page 98: ...OHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or ...

Page 99: ...switches 3 11 Hazard switch 3 12 Headlight beams adjusting 3 22 Headlight bulb replacing 6 30 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 28 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 33 L...

Page 100: ...ool kit 6 1 Troubleshooting 6 34 Troubleshooting charts 6 35 Turn signal indicator lights 3 3 Turn signal light or tail brake light bulb replacing 6 32 Turn signal switch 3 11 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels 6 20 Windshield position adjusting switch 3 12 U3P620E0 book Page 2 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 101: ...U3P620E0 book Page 3 Tuesday January 24 2006 10 47 AM ProCarManuals com ...

Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2005 12 0 3 2 CR E ProCarManuals com ...

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