Yamaha FJR1300ASW Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

EAU36501

Rear brake light switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, have a Yamaha dealer ad-
just the brake light switch.

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.

EAU43431

Front brake pads

The front brake calipers are equipped
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 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.

1. Brake pad wear indicator groove

1. Lining thickness

U2D221E0.book Page 19 Wednesday, January 24, 2007 3:52 PM

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Summary of Contents for FJR1300ASW

Page 1: ...2D2 28199 21 FJR1300ASW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U2D221E0 book Page 2 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 3: ...l advantages of your FJR1300ASW The owner s man ual 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 January 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2D221E0 book Page 2 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 6: ...ion 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 6 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 29 Replacing the license plate light bulb 6 30 Auxiliary light bulb 6 30 Troubleshooting 6 31 Troubleshooting charts 6 32 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 U2D221E0 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 U2D221E0 book Page 5 Wednesday January 24 2007 3 52 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 U2D221E0 book Page 6 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 14: ...t page 3 19 7 Final gear oil filler bolt page 6 11 8 Final gear oil drain bolt page 6 11 9 YCC S clutch fluid reservoir page 6 20 10 Shock absorber assembly spring preload adjusting lever page 3 27 11 Air filter element page 6 14 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 U2D221E0 book Page 1 Wednesda...

Page 15: ...ld page 3 13 5 Battery page 6 26 6 Main fuse page 6 27 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 27 10 Rear brake fluid reservoir page 6 20 U2D221E0 book Page 2 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 16: ...nction display page 3 7 6 Front brake fluid reservoir page 6 20 7 Right handlebar switches page 3 13 8 Brake lever page 3 16 9 Throttle grip page 6 15 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 U2D221E0 book Page 3 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 17: ...ally by the 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 EAU10973 Immobilizer system This vehicle is equipped with an immo bilizer...

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: ...ne 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 7 for an explanation of the self diagnosis de vice YCC S indicator and warning light This indicat...

Page 22: ...not 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 ...

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: ...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 brake ...

Page 33: ...ction 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 experience the pulsating at the brake lever or brake pedal when the ABS is oper ating However special tools are required so please consult your Yamaha dealer when performing this test EAU13072 Fuel tank cap To open the fuel tank cap Open the fuel tank cap...

Page 34: ...lling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13332 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...

Page 35: ...d gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other 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...

Page 36: ... 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 2 Install the passenger seat NOTE Make sure that the seats are prop erly secured before riding The rider seat height can be ad justed to change the riding posi tion See page 3 21 1 Projection 2 Seat holder 1 Rider seat lock lever 2 Rider seat 1 Projection 2 Seat ...

Page 37: ...juster 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 5 Insert the projection on the front of the rider seat into seat holder B as shown 1 Low position 2 High position 1 Rider seat height position adjuster 1 Rider seat holder cover 1 Rider seat height position...

Page 38: ...ider 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 6 Align the projection on the bottom of the rider seat with the L posi tion slot and then push the rear of the seat down to lock it in place as shown 7 Install the passenger seat NOTE Make sure that the seats are properly secured be...

Page 39: ...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 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...

Page 40: ...s 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 cowl ings The cowlings can be tilted back 30 mm 1 18 in for added ventilation to suit the riding co...

Page 41: ...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 42: ...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 43: ... 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 ECA...

Page 44: ...ore 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 t...

Page 45: ...n or damaged stop using the grip warmers and replace the grips WARNING EWA14510 Do not turn the grip warmer knob while the vehicle is moving EAU15301 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignitio...

Page 46: ... up but neither brake is ap plied It prevents starting when either brake is applied but the sidestand is still down It cuts the running engine when the sidestand 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 malfunction is noted ha...

Page 47: ...e 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 This check is most reliable if performed with a warmed up engine 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 de...

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 19 6 20 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 22 Brake lever Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 23 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 23 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: ... transmission in gear and the sidestand is up WARNING EWA14540 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 30 Always apply the front or rear brake while the main switch is in the ON position and the trans mission is in gear otherwise the rear wheel will move freely Never ride with the sidestand down 1 Turn th...

Page 53: ...r The hand shift lever has to be enabled by pressing the hand shift control switch prior to being used Refer to page 3 15 for the shift pedal operation and to pages 3 14 and 3 16 for the hand shift lever operation The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly or push the side of the hand shift lever...

Page 54: ...shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing mate...

Page 55: ...s turned to OFF and the transmission is in gear the rear wheel cannot be moved WARNING EWA14521 Always stop the engine using the main switch When the en gine stop switch has been used in an emergency be sure to ap ply the front or rear brake while the main switch is still on as the clutch automatically disengag es a few seconds after the en gine is turned off and the rear wheel will move freely Si...

Page 56: ...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 19 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 57: ... 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 YCC S 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...

Page 58: ...rews are properly tightened 15 Brake lever and brake pedal pivot shafts Apply silicone grease lightly 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assem bly Check operation and shock absorber for oil leakage 21 Rear suspen...

Page 59: ...ke switches Check operation 28 Moving parts and ca bles Lubricate 29 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 30 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damaged parts if necessary 31 Muffler and exhaust pipe Check the screw clamp f...

Page 60: ...uid levels Every two years replace the internal components of 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 U2D221E0 book Page 5 Wednesday January 24 2007 3 52 PM ProCarManuals com ...

Page 61: ... remove 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 EAU39591 Panel B To remove the panel 1 Remove the seats See page 3 19 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 3 Quick...

Page 62: ... the panel 1 Remove the seats See page 3 19 2 Remove the bolt and the quick fas tener screws and then take the panel off To install the panel 1 Place the panel in the original posi tion and then install the bolt and the quick fastener screws 2 Install the seats 1 Panel B 2 Bolt 3 Quick fastener screw 1 Panel C 2 Bolt 3 Quick fastener screw U2D221E0 book Page 7 Wednesday January 24 2007 3 52 PM Pro...

Page 63: ...rating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plu...

Page 64: ...ed at the bottom left side of the crank case NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Plac...

Page 65: ...asher for damage and re place it if necessary 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf Recommended engine oil See ...

Page 66: ...A10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 10 Turn the engine off and then check the oil level and correct it if necessary EAU20011 Final gear oil The final gear 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...

Page 67: ...tall the final gear oil drain bolt and then tighten it to the specified torque 4 Add the recommended final gear oil to the brim of the filler hole 5 Install the oil filler bolt and then tighten it to the specified torque 6 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 oil level Tightening torque Fi...

Page 68: ... coolant 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 reservoir cap 4 Add coolant or distilled water to raise the coolant to the maximum level mark install the coolant res ervoir cap CAUTION ECA...

Page 69: ... the coolant temperature in the radia tor If the engine overheats see page 6 32 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 70: ...U21382 Checking the throttle cable 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 cleara...

Page 71: ...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 72: ...ation 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 ...

Page 73: ...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 74: ... 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 75: ...C S clutch fluid reservoir is located behind panel B See page 6 6 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 76: ...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 77: ...ntervals specified in the periodic maintenance chart EAU23132 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 lubricants Brake pedal Silicone grease Shift pedal Lithium soap based grease all purpose grease U2D221E0 book Page 22 Wednesday January 24 ...

Page 78: ...nd 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 grease Recomme...

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: ...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 YCC S motor control fuse 7 Headlight fuse 8 Signaling system fuse 9 ABS control ...

Page 83: ...aha 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 control unit fuse 10 0 A A...

Page 84: ...seat See page 3 19 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 85: ...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 U2D221E0 book Page 30 W...

Page 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ... 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 92: ... 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 93: ... 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 gal Fuel reserve amount 5 ...

Page 94: ... 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 ope...

Page 95: ...D 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 96: ... 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 97: ...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 98: ...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 28 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 99: ...g 6 22 Tires 6 16 Tool kit 6 1 Troubleshooting 6 31 Troubleshooting charts 6 32 Turn signal indicator lights 3 4 Turn signal light or tail brake light bulb replacing 6 29 Turn signal switch 3 13 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 25 Wheels 6 18 Windshield position adjusting switch 3 13 Y YCC S clutch 6 18 YCC S system 3 1 U2D221E0 book Page 2 Wedne...

Page 100: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 101: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 02 0 3 1 CR E ProCarManuals com ...

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