Yamaha FJR1300AW Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

6

EAU21311

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 engine and warm it up for sev-
eral minutes at 1000–2000 r/min while
occasionally revving it to 4000–5000
r/min.

NOTE:

The engine is warm when it quickly re-
sponds to the throttle.

EAU21382

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 clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.

Engine idling speed:

1000–1100 r/min

1. Throttle cable free play

U3P621E0.book Page 16 Friday, October 20, 2006 10:29 AM

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Summary of Contents for FJR1300AW

Page 1: ...3P6 28199 21 FJR1300AW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U3P621E0 book Page 2 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 3: ...all advantages of your FJR1300AW 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: ...ve 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 m...

Page 5: ... by Yamaha Motor Co Ltd 1st edition October 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U3P621E0 book Page 2 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 6: ...MPORTANT 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 11 Coolant 6 13 Cleaning the air f...

Page 7: ...ight bulb or a tail brake light bulb 6 30 Replacing the license plate light bulb 6 31 Auxiliary light bulb 6 32 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 U3P621E0 book Page 2 Friday October 20 2006 1...

Page 8: ...een 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 ca...

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: ...me 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: ...ntilation 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 ...

Page 12: ...INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3P621E0 book Page 5 Friday October 20 2006 10 29 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 U3P621E0 book Page 6 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 14: ...e 3 17 6 Passenger seat page 3 17 7 Final gear oil filler bolt page 6 11 8 Final gear oil drain bolt page 6 11 9 Shock absorber assembly spring preload adjusting lever page 3 26 10 Air filter element page 6 14 11 Shift pedal page 3 14 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 U3P621E0 book Page 1 Friday October 20 2006 10 29...

Page 15: ...eld page 3 11 5 Battery page 6 27 6 Main fuse page 6 28 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 26 10 Rear brake fluid reservoir page 6 21 U3P621E0 book Page 2 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 16: ...er page 3 6 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 16 12 Main switch steering lock page 3 2 13 Headlight beam adjusting knob page 3 22 14 Grip warmer adjusting knob page 3 27 U3P621E0 book Page 3 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 17: ...IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re re...

Page 18: ...y red bow keep it in a safe place and only use it for code re registering EAU26811 ON All electrical circuits are supplied with power the meter lighting 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 ...

Page 19: ...switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU39460 Parking The steering is locked and the tail lights license plate light and auxiliary lights are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked b...

Page 20: ...s warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system See page 3 6 for an explanation of the self diagnosis de vice The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha deal...

Page 21: ...r check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled This model is also equipped with a self diagnosis device for the immobilizer system See page 3 6 for an explan...

Page 22: ... the multi function display The multi function display is equipped with the following an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled on the fuel reserve a clock a fuel meter a coolant temperature meter a transmission gear display an ambient temperature d...

Page 23: ...1 TRIP 2 F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the SELECT button for at least one second while the display is flash ing If you do not reset the fuel reserve tripmeter manually it will reset itself au tomatically and the display will return to the prior mode after refueling and trav eling 5 km 3 mi Clock To set the clock 1 Push the SELECT button and RESET...

Page 24: ...oolant temperature meter With the key in the ON position the coolant temperature meter indicates the temperature of the coolant When the key is turned to ON all of the dis play segments of the coolant tempera ture meter will appear one after the other and then disappear in order to test the electrical circuit The coolant temperature varies with changes in the weather and engine load If the top seg...

Page 25: ...mperature falls be low 9 C a lower temperature than 9 C will not be displayed If the ambient temperature climbs above 50 C a higher temperature than 50 C will not be displayed The accuracy of the temperature reading may be affected when riding slowly approximately under 20 km h or when stopped at traffic signals railroad crossings etc Instantaneous fuel consumption mode The instantaneous fuel cons...

Page 26: ...displayed To reset the average fuel consumption display push the RESET button to se lect the mode again and then push the RESET button for 1 second while the display is flashing NOTE To switch between the two aver age fuel consumption displays push the RESET button for 1 second when either display is shown After resetting an average fuel consumption display _ _ _ will be shown for that display unt...

Page 27: ...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 key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start t...

Page 28: ...ey is turned to OFF the windshield will automatically return to the lowest position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the...

Page 29: ...oward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch lever position adjusting dial To adjust the distance between the clutch lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appro...

Page 30: ...ndlebar 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...

Page 31: ...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 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 ca...

Page 32: ...illing 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 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 d...

Page 33: ...ed 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 passenge...

Page 34: ...t 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 19 1 Projection 2 Seat holder 1 Rider seat lock lever 2 Rider seat 1 Projection 2 Seat...

Page 35: ...djuster 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 positio...

Page 36: ...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 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 b...

Page 37: ... storage compart ment B Do not exceed the maximum load of 212 kg 467 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 the accessory box 1 Fold t...

Page 38: ...of the head light beams It may be necessary to ad just the headlight beams to increase visibility and help prevent blinding on coming drivers when carrying more or less load than usual Obey local laws and regulations when adjusting 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 position The ha...

Page 39: ...open 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 U3P621E0 ...

Page 40: ... 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 g...

Page 41: ...TE 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 42: ...e 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 t...

Page 43: ...re 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 gri...

Page 44: ...d 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 EAU15321 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is u...

Page 45: ...ine 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 ...

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: ...raulic 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 add recommended brake flu...

Page 49: ...mooth Lubricate pedal pivoting points if necessary 6 23 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 24 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches ...

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: ...ne 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 A...

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 U3P621E0 book Page 4 Friday October 20 2006 10 29 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: ... properly tightened 15 Brake and clutch lever pivot shafts Lubricate with lithium soap based grease 16 Brake and shift pedal pivot shafts 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 Re...

Page 57: ...es 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 for looseness 32 Lights signals and switches Check ope...

Page 58: ...rly check and if necessary correct the brake and clutch fluid levels Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged U3P621E0 book Page 5 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 59: ...o 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 17 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 Quic...

Page 60: ...e the panel 1 Remove the seats See page 3 17 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 U3P621E0 book Page 7 Friday October 20 2006 10 29 AM ProC...

Page 61: ...erating 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 pl...

Page 62: ...ted 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 Pla...

Page 63: ...washer 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 64: ...emains 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 final gear oil must be changed as follows at the i...

Page 65: ...stall 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 F...

Page 66: ...e 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 EC...

Page 67: ...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 EAU20471 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean...

Page 68: ... seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 7 Install the air filter case cover by in stalling the screws CAUTION ECA15410 Make sure 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 fas...

Page 69: ...AU21382 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 clear...

Page 70: ...ely 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 ...

Page 71: ...mation 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 72: ... 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 characteristics and a short ened tire life Ride at moderate speeds after...

Page 73: ...ch 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 pa...

Page 74: ...r clutch fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type 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 neg...

Page 75: ...rake and clutch master cylinders and cali pers as well as the brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and th...

Page 76: ...e lubricated at the intervals specified in the periodic maintenance chart EAU23131 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 all pur pose grease U3P621E0 book Page 23 Friday October 20 2006 10 29 AM ProCarMa...

Page 77: ...nd and sidestand The operation of the centerstand and sidestand should be checked before each ride and the 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 Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant ...

Page 78: ...d as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING 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...

Page 79: ...hecked 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 ...

Page 80: ... the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with...

Page 81: ...ds are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer...

Page 82: ...mmediately blows again have a Yamaha dealer check the electrical system 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 Ignition fuse 10 Fuel injection system fuse 11 Auxiliary DC jack fuse 12 Spare fuse Specified fuses Main fuse 50 0 A Headlight f...

Page 83: ... rear turn signal light bulb or a tail brake light bulb 1 Remove the passenger 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 c...

Page 84: ...the socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws 1 Screw 2 License plate light unit 1 License plate light bulb U3P621E0 book Page 31 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 85: ...mple can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitati...

Page 86: ...no 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 Batt...

Page 87: ...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 system for leakage Hav...

Page 88: ...ets 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 grease...

Page 89: ...t 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 motorcycle wit...

Page 90: ...d 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 91: ...e 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 92: ...pe Shaft drive gear oil Part No 9079E SH001 00 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 r...

Page 93: ...0 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 op...

Page 94: ...ndicator light LED 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 ...

Page 95: ...n 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 96: ...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 97: ...ndlebar position adjusting 3 22 Handlebar switches 3 11 Hazard switch 3 13 Headlight beams adjusting 3 22 Headlight bulb 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 5 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 License p...

Page 98: ...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 12 V Valve clearance 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels 6 19 Windshield position adjusting switch 3 12 U3P621E0 book Page 2 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 99: ...U3P621E0 book Page 3 Friday October 20 2006 10 29 AM ProCarManuals com ...

Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 11 0 3 1 CR E ProCarManuals com ...

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