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PERIODIC MAINTENANCE AND MINOR REPAIR

6-26

EAU23280

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 maintenance and lubrication
chart.

1. Place a stand under the engine to

raise the front wheel off the
ground.

WARNING

EWA10750

Securely support the vehicle so that
there is no danger of it falling over.

2. Hold the lower ends of the front

fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.

U2D222E0.book Page 26 Wednesday, October 17, 2007 3:50 PM

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Summary of Contents for FJR1300AS(X)

Page 1: ...2D2 28199 22 FJR1300ASX OWNER S MANUAL ProCarManuals com ...

Page 2: ...U2D222E0 book Page 2 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 3: ...ll advantages of your FJR1300ASX 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 ...

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 October 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2D222E0 book Page 2 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 6: ...tion 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 4 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 7 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Final gear oil 6...

Page 7: ...rear turn signal light bulb or a tail brake light bulb 6 30 Replacing the license plate light bulb 6 31 Auxiliary light bulb 6 31 Troubleshooting 6 32 Troubleshooting charts 6 33 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 Motorcycle noise regulation for Australia 9 2 U2D222E0 book Page 2 Wednes...

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: ...gles 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 syst...

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 U2D222E0 book Page 5 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 13: ... 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 U2D222E0 book Page 6 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 14: ...t page 3 20 7 Final gear oil filler bolt page 6 12 8 Final gear oil drain bolt page 6 12 9 YCC S clutch fluid reservoir page 6 21 10 Shock absorber assembly spring preload adjusting lever page 3 28 11 Air filter element page 6 15 12 Shift pedal page 3 15 13 Engine oil filler cap page 6 9 14 Engine oil filter cartridge page 6 9 15 Engine oil level check window page 6 9 U2D222E0 book Page 1 Wednesda...

Page 15: ...ld page 3 13 5 Battery page 6 27 6 Main fuse page 6 28 7 Front fork compression damping force adjusting screw page 3 26 8 Brake pedal page 3 16 9 Shock absorber assembly rebound damping force adjusting knob page 3 28 10 Rear brake fluid reservoir page 6 21 U2D222E0 book Page 2 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 16: ...nction display page 3 7 6 Front brake fluid reservoir page 6 21 7 Right handlebar switches page 3 13 8 Brake lever page 3 16 9 Throttle grip page 6 16 10 Main switch steering lock page 3 3 11 Headlight beam adjusting knob page 3 24 12 Grip warmer adjusting knob page 3 29 13 Hand shift lever page 3 16 U2D222E0 book Page 3 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 17: ...MCU ac cording to engine r min engine require ments and riding conditions See Handlebar switches page 3 13 and OPERATION AND IMPORTANT RIDING POINTS page 5 1 for further explanation of this system NOTE This is not an automatic transmission only the clutch system is automatic The gears must be shifted by the rider EAU10974 Immobilizer system This vehicle is equipped with an immo bilizer system to h...

Page 18: ... 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 in a safe place Do not submerse any key in wa ter Do not expose any key to exces sively high temperatures Do not place any key close to magnets this includes but not limited to products such as speakers e...

Page 19: ...ing 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 20: ...ectrical 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 to the left or...

Page 21: ...e trouble YCC S indicators and warning light Engine trouble indicator and warning light This indicator is displayed and the warning light comes on or flashes when an electrical circuit monitoring the en gine is defective When this occurs have a Yamaha dealer check the self diagnosis system See page 3 12 for an explanation of the self diagnosis de vice YCC S indicator and warning light This indicat...

Page 22: ...ot to cause the wheels to lock during emergen cy braking If the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on or remains on have a Yamaha dealer check the electrical circuit EAU38620 Immobilizer system indicator l...

Page 23: ...ro 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 9000 r min and above EAU41171 Multi function display WARNING EWA14430 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following an odometer which shows the to tal distance travel...

Page 24: ...econds When approximately 5 5 L 1 45 US gal 1 21 Imp gal of fuel remains in the fuel tank the display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case pushing the SELECT button switches the display between the vari ous tripmeter and odometer modes in the following order F TRIP ODO TRIP 1 TRIP 2 F TRIP To reset...

Page 25: ...ne after the other and then disappear in order to test the electrical circuit NOTE This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective all the display segments will start flashing If this occurs have a Yamaha dealer check the electrical cir cuit Coolant temperature meter With the key in the ON position the coolant temperature meter indicates the temperat...

Page 26: ...umption mode km L or L 100 km and the average fuel consumption mode AV_ _ _ km L or AV_ _ _ L 100 km in the following order Air km L or L 100 km AV_ _ _ km L or AV_ _ _ L 100 km Air Ambient temperature mode This display shows the ambient tem perature from 9 C to 50 C in 1 C in crements The temperature displayed may vary from the ambient tempera ture NOTE If the ambient temperature falls be low 9 C...

Page 27: ...e This display shows the average fuel consumption since it was last reset The average fuel consumption display can be set to either AV_ _ _ km L or AV_ _ _ L 100 km When the average fuel consumption mode is selected the display flashes for five seconds and then depending on the unit set AV_ _ _ km L aver age distance that can be traveled using 1 0 L of fuel or AV_ _ _ L 100 km av erage amount of f...

Page 28: ...n display will indicate a two digit error code when the key is turned to ON NOTE If the multi function display indicates er ror code 52 this could be caused by transponder interference If this error appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer ke...

Page 29: ...l lights push the switch in after it has re turned to the center position EAU12493 Windshield position adjusting switch To move the windshield up push this switch in direction a To move the windshield down push the switch in di rection b NOTE When the key is turned to OFF the windshield will automatically return to the lowest position 1 Pass switch 2 Windshield position adjusting switch 3 Dimmer s...

Page 30: ...on 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 CAUTION ECA10061 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU40381 Hand shift ...

Page 31: ... shift gears unless the main switch is in the ON position The shift pedal can be adjusted to three positions to suit the rider s preference To adjust the shift pedal position 1 Remove the shift pedal by remov ing the bolt 2 Move the shift pedal to the desired position 3 Install the bolt and then tighten it to the specified torque 1 Shift pedal 1 Shift pedal 2 Bolt 3 Standard position Tightening to...

Page 32: ...grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU39540 Brake pedal The brake pedal is on the right side of the vehicle This model is equipped with a unified brake system When pressing down on the brake ped al the rear brake and a portion of the front b...

Page 33: ...nder the seat and if the brake lever or brake ped al are even slightly applied a vi bration can be felt at the lever and pedal but these do not indicate a malfunction When the ABS is activated the brakes are operated in the usual way A pulsating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner to experien...

Page 34: ...s the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler tube as show...

Page 35: ... reduce maintenance costs EAU13442 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoli...

Page 36: ... down to lock it in place 2 Remove the key Rider seat To remove the rider seat 1 Remove the passenger seat 2 Push the rider seat lock lever lo cated under the back of the rider seat to the left as shown and then pull the seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place...

Page 37: ...ider 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 20 2 Remove the rider seat height posi tion adjuster by pulling it upward 3 Move the rider seat holder cover to the lower position as shown 4 Install the rider seat height position adjuster so that the H mark is aligned with the match mark 1 Low po...

Page 38: ...ion 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 5 Insert the projection on the front of the rider seat into seat holder A as shown 1 Rider seat height position adjuster 2 H mark 3 Match mark 1 Projection 2 Seat holder B for high position 3 Rider seat holder...

Page 39: ...ad limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of 208 kg 459 lb for the ve hicle EAU39480 Accessory box The accessory box is located beside the meter panel To open the accessory box 1 Insert the key into the main switch and then turn it to ON 2 Push the accessory box button and then open the accessory box lid 3 Turn the key to OFF to preserve the battery To close...

Page 40: ...he height of the headlight beams It may be neces sary to adjust the headlight beams to increase visibility and help prevent blinding oncoming drivers when carry ing more or less load than usual Obey local laws and regulations when adjust ing the headlights To raise the headlight beams turn the knobs in direction a To lower the headlight beams turn the knobs in di rection b EAU39641 Handlebar posit...

Page 41: ...pen posi tion and then install the quick fas tener screws To close a cowling 1 Remove the quick fastener screws 2 Push the cowling to the closed po sition and then install the quick fastener screws NOTE Make sure that the cowling is properly installed before riding 1 Closed position 2 Open position 3 Cowling 1 Quick fastener screw 1 Open position 1 Quick fastener screw 1 Closed position U2D222E0 b...

Page 42: ...WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate gr...

Page 43: ...E Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as ...

Page 44: ... rebound damping turn the adjusting knob in di rection b WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before 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 th...

Page 45: ...e turn the knob in direction b Align the mark on the knob with OFF to turn the grip warmers off NOTE When the vehicle is stopped or travel ing at extremely low speeds e g in traffic jams the grip warmer tempera ture is lower than when traveling at higher speeds CAUTION ECA15520 Be sure to wear gloves when us ing the grip warmers If the ambient temperature is 20 C 68 F or higher do not set the grip...

Page 46: ...in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU40522 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch and brake light switches has the following func tions It prevents starting when the...

Page 47: ...e the sidestand down Does the engine stall After the engine has stalled 11 Move the sidestand up 12 Release the brake 13 Push the start switch Does the engine start The system is OK The vehicle can be ridden The neutral the brake switch or the YCC S system may be defective The vehicle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The vehicle should not...

Page 48: ...ed 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 23 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 49: ...refore 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 prop...

Page 50: ...ve Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 20 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...

Page 51: ... is smooth Lubricate pedal pivoting points if necessary 6 23 Brake lever Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 24 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check op...

Page 52: ...a turnover be sure to turn the main switch to OFF and then to ON Fail ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAU41181 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The front or rear brake is applied with the transmission in the neutral po...

Page 53: ...ght should be on otherwise have a Yamaha dealer check the electrical cir cuit 3 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt CAUTION ECA11130 For maximum engine...

Page 54: ...ate lubrica tion may damage the transmis sion Always return the throttle to the closed position while changing gears to avoid damaging the en gine transmission and drive train which are not designed to withstand the shock of forced shifting NOTE When shifting from neutral to first gear the engine speed must be lower than approximately 1300 r min and the sidestand must be up Shifting up is impossib...

Page 55: ...ar tridge or element replaced 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10310 Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU40581 Parking When parking stop the engine by turn ing the main switch to OFF and then remove the key NOTE...

Page 56: ...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 U2D222E0 book Page 5 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 57: ...liar 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 20 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 ne...

Page 58: ...data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Air filter element Clean Replace 5 YCC S clutch Check ope...

Page 59: ...mage 12 Swingarm Check operation and for exces sive play Lubricate with lithium soap based grease Every 50000 km 30000 mi 13 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Brake lever pivot shaft Lubricate with silicone grease NO ...

Page 60: ... Rear suspension re lay arm and con necting arm pivoting points Check operation Lubricate with lithium soap based grease 23 Fuel injection Adjust engine idling speed and synchronization 24 Engine oil Change Check oil level and vehicle for oil leakage 25 Engine oil filter car tridge Replace 26 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years NO ITEM CHECK OR M...

Page 61: ...rottle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary 32 Muffler and exhaust pipe Check the screw clamp s for looseness 33 Lights signals and switches Check operation Adjust h...

Page 62: ... the brake master cylinders and calipers as well as YCC S clutch master and release cylinders and change the brake and YCC S clutch fluids Replace the brake and YCC S clutch hoses every four years and if cracked or damaged U2D222E0 book Page 6 Wednesday October 17 2007 3 50 PM ProCarManuals com ...

Page 63: ...the panel Remove 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 EAU39592 Panels B and C To remove one of the panels 1 Remove the seats See page 3 20 2 Remove the bolts and the quick fastener screws and then take the panel off 1 Panel A 1 Panel B 1 Panel C 1 Panel A 2 Bolt ...

Page 64: ...ugs 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 operating im properly Do not attempt to diagnose such p...

Page 65: ... 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 66: ...nder the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 6 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1 Eng...

Page 67: ...n 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 enters the crankcase 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torq...

Page 68: ...ar case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle In addi tion the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrica tion chart WARNING EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To ...

Page 69: ...final gear case 4 Install the final gear oil drain bolt and then tighten it to the specified torque 5 Refill with the recommended final gear oil to the brim of the filler hole 6 Install the oil filler bolt and then tighten it to the specified torque 7 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Final gear oil filler bolt 2 Final gear oil drain bolt 3 Correct o...

Page 70: ...lant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove the coolant reservoir cap 4 Add coolant or distilled water to raise the coolant to the maximum level mark install the coolant res ervoir cap CAUTION...

Page 71: ... the coolant temperature in the radia tor If the engine overheats see page 6 33 for further instructions EAU33030 Changing the coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant EAU40370 Air filter element The air f...

Page 72: ...e free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha ...

Page 73: ...ly pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum l...

Page 74: ...ion This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely in...

Page 75: ...he wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt 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 ...

Page 76: ... with two sets of 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 a brake pad for wear check its wear indicator groove If a brake pad has worn to the point that the wear indi cator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear br...

Page 77: ...C S clutch fluid reservoir is located behind panel B See page 6 7 Observe these precautions When checking the fluid level make sure that the top of the brake and YCC S clutch fluid reservoirs are level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or YCC S clutch performance Refill with the same type of brake fluid Mixing f...

Page 78: ...specified in the NOTE after the periodic maintenance and lubrication chart In addition have the oil seals of the brake and YCC S clutch master cyl inders and calipers as well as the brake and YCC S clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake and YCC S clutch hoses Replace every four years EAU23100 Checking and ...

Page 79: ... should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease U2D222E0 book Page 23 Wednesday October 17 2007 3 50 PM ProCarManuals com...

Page 80: ...e pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10740 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Silicone grea...

Page 81: ...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 82: ...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 83: ...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 the...

Page 84: ...key to OFF and turn off the electrical circuit in question 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 ABS solenoid fuse 7 Fuel injection system fuse 8 Headlight fuse 9 Signaling system fuse 10 ABS control unit fuse 11 Ignition fuse 12 Auxiliary ...

Page 85: ...ely blows again have a Yamaha dealer check the electrical system EAU40360 Headlight bulb If a headlight does not come on have a Yamaha dealer check its electrical cir cuit or replace the bulb Specified 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 Backup fuse 10 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS ...

Page 86: ...seat See page 3 20 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 87: ...l 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 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 Screw 2 License plate light unit 1 License plate light bulb U2D222E0 book Page 31 W...

Page 88: ...ting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a ...

Page 89: ...o compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Batte...

Page 90: ...own on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have...

Page 91: ...s with plas tic bags 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 and wheel axles Always rinse the dirt and de greaser ...

Page 92: ...ered 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 carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the ...

Page 93: ... using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26241 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow ...

Page 94: ... spark plug electrodes while turning the engine over 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 turn the wheels a little every month in order to prevent the tires from becoming ...

Page 95: ...t 3 52 Imp qt Final gear oil Type Shaft 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 ga...

Page 96: ...70 kPa 39 psi 2 70 kgf cm Rear 290 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 o...

Page 97: ...ndicator 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 fuse 30 0 A A...

Page 98: ... 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 99: ...HIBITED 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 e...

Page 100: ...ndlebar position adjusting 3 24 Handlebar switches 3 13 Hand shift control switch 3 14 Hand shift lever 3 16 Hazard switch 3 14 Headlight beams adjusting 3 24 Headlight bulb 6 29 High beam indicator light 3 5 Horn switch 3 14 I Identification numbers 9 1 Ignition circuit cut off system 3 30 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Indicator and warning lights 3 4 K Key identif...

Page 101: ...g 6 23 Tires 6 17 Tool kit 6 1 Troubleshooting 6 32 Troubleshooting charts 6 33 Turn signal indicator lights 3 4 Turn signal light or tail brake light bulb replacing 6 30 Turn signal switch 3 13 V Valve clearance 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 26 Wheels 6 19 Windshield position adjusting switch 3 13 Y YCC S clutch 6 19 YCC S system 3 1 U2D222E0 book Page 2 Wedne...

Page 102: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 103: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 104: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 11 0 3 1 CR E ProCarManuals com ...

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