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PERIODIC MAINTENANCE AND MINOR REPAIR

6-28

6

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.

U2D21AE0.book Page 28 Monday, June 26, 2006 2:18 PM

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Summary of Contents for FJR13AEV(C)

Page 1: ...2D2 28199 1A FJR13AEV C OWNER S MANUAL LIT 11626 19 87 ...

Page 2: ...EAU10041 U2D21AE0 book Page 1 Monday June 26 2006 2 18 PM ...

Page 3: ...orcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high ...

Page 4: ... consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow W...

Page 5: ... TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without notice U2D21AE0 book Page 2 Monday June 26 2006 2 18 PM ...

Page 6: ...poration U S A 1st edition June 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 19 87 AFFIX DEALER LABEL HERE U2D21AE0 book Page 3 Monday June 26 2006 2 18 PM ...

Page 7: ...ND IMPORTANT RIDING POINTS 5 1 Starting the engine 5 1 Shifting 5 2 Engine break in 5 4 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing panels 6 8 Checking the spark plugs 6 10 Canister for California only 6 11 Engi...

Page 8: ...t bulb or a tail brake light bulb 6 32 Replacing the license plate light bulb 6 33 Troubleshooting 6 33 Troubleshooting charts 6 34 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE ...

Page 9: ...ents have been 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 m...

Page 10: ...hield or goggles 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 ...

Page 11: ...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 12: ...d equate ventilation 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...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2D21AE0 book Page 5 Monday June 26 2006 2 18 PM ...

Page 14: ...SAFETY INFORMATION 1 6 1 1 California only 2 California only 4 3 kg 7 lbs 3TB 24877 A0 LOAD LIMIT 3 California only PRESS REGULATOR U2D21AE0 book Page 6 Monday June 26 2006 2 18 PM ...

Page 15: ...line or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 270 kPa 2 70 kgf cm2 39psi 290 kPa 2 90 kgf cm2 42psi 270 kPa 2 70 kgf cm2 39psi 290 kPa 2 90 kgf cm2 42psi 3P6 21668 00 U2D21AE0 book Page 7 Monday June 26 2006 2 18 PM ...

Page 16: ...ssenger seat page 3 16 7 Final gear oil filler bolt page 6 14 8 Final gear oil drain bolt page 6 14 9 YCC S clutch fluid reservoir page 6 23 10 Shock absorber assembly spring preload adjusting lever page 3 24 11 Air filter element page 6 17 12 Shift pedal page 3 12 13 Engine oil filler cap page 6 11 14 Engine oil filter cartridge page 6 11 15 Engine oil level check window page 6 11 U2D21AE0 book P...

Page 17: ...0 4 Windshield page 3 10 5 Battery page 6 29 6 Main fuse page 6 30 7 Front fork compression damping force adjusting screw page 3 23 8 Brake pedal page 3 13 9 Shock absorber assembly rebound damping force adjusting knob page 3 24 10 Rear brake fluid reservoir page 6 23 U2D21AE0 book Page 2 Monday June 26 2006 2 18 PM ...

Page 18: ...5 5 Multi function display page 3 5 6 Front brake fluid reservoir page 6 23 7 Right handlebar switches page 3 10 8 Brake lever page 3 13 9 Throttle grip page 6 17 10 Main switch steering lock page 3 1 11 Headlight beam adjusting knob page 3 21 12 Grip warmer adjusting knob page 3 26 13 Hand shift lever page 3 13 U2D21AE0 book Page 3 Monday June 26 2006 2 18 PM ...

Page 19: ...ording to engine r min engine require ments and riding conditions See Handlebar switches page 3 10 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 EAU10460 Main switch steering lock The main switch steering lock controls the ignition and li...

Page 20: ...or LOCK while the vehicle is moving otherwise the electrical systems will be 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 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 right ...

Page 21: ...AU40512 Engine 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 5 for an explanation of the self diagnosis de vice YCC S indicator and warning light ...

Page 22: ...AU40870 ABS warning light If this warning light comes on or flashes while riding the ABS may be defective If this occurs have a Yamaha dealer check the system as soon as possible See page 3 14 WARNING EWA10081 If the ABS warning light comes on or flashes while riding the brake sys tem reverts to conventional braking Therefore be careful not to cause the wheels to lock during emergen cy braking If ...

Page 23: ...return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 9000 r min and above EAU40850 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 dis...

Page 24: ...s for five seconds 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 TRIP 1 TRIP 2 ODO F T...

Page 25: ...ill appear one 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 ...

Page 26: ...n mode MPG and the av erage fuel consumption mode AV_ _ _ MPG in the following order Air MPG AV_ _ _ MPG Air Ambient temperature mode This display shows the ambient tem perature from 16 F to 122 F in 1 F in crements The temperature displayed may vary from the ambient tempera ture NOTE If the ambient temperature falls be low 16 F a lower temperature than 16 F will not be displayed If the ambient te...

Page 27: ...1 0 US gal of fuel is dis played NOTE To reset the average fuel con sumption display push the RE SET button to select the mode again and then push the RESET button for 1 second while the dis play is flashing After resetting the average fuel consumption display _ _ _ will be shown for that display until the vehicle has traveled 1 km 0 6 mi CAUTION ECA15472 If there is a malfunction will be displaye...

Page 28: ... Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re turned to the center position 1 Windshield position adjusting switch 2 Dimme...

Page 29: ...for starting instruc tions prior to starting the engine EAU12764 Hazard switch With the key in the ON position turn this switch to to turn on the hazard 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...

Page 30: ... pedal is located on the left side of the engine Neutral is at the bottom po sition NOTE It is impossible to 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 ...

Page 31: ...dlebar 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 32: ... 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 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 EAU13070 Fuel tank cap To open the fuel tank cap Open the f...

Page 33: ...and expands Avoid spilling 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 EAU13300 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 Yama...

Page 34: ...ake 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 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 D...

Page 35: ...eat 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 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 18 1 Projection 2 Seat holder 1 Rider seat lock lever 2 Rider seat 1 Projec...

Page 36: ...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 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 hei...

Page 37: ...nstall 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 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 properl...

Page 38: ...h 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 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 ex...

Page 39: ...adlight beams 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 t...

Page 40: ...g is properly 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 Close...

Page 41: ...E Align the 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 pr...

Page 42: ...er 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 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...

Page 43: ...ormation 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 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 ...

Page 44: ... becomes worn 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...

Page 45: ...ide stand is 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...

Page 46: ...es 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 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 swit...

Page 47: ... engine turned 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 20 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 circ...

Page 48: ...equences Therefore 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 ...

Page 49: ...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 fluid to specified level Check hydraulic system for leakage 6 22 6 23 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 ...

Page 50: ...at operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake lever Make sure that operation is smooth Lubricate lever pivoting point if necessary 6 26 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switc...

Page 51: ...n 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 27 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 the key to ON and...

Page 52: ...ssing the hand shift control switch prior to being used Refer to page 3 12 for the shift pedal operation and to pages 3 11 and 3 13 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 repeatedly until the neutral indicator light c...

Page 53: ...n shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU41250 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 25 km h 15 5 mi h If the engine is about to stall or runs very roughly use the brakes to stop the motor cycle 3 Shift the transmission into the neu tra...

Page 54: ...oil filter car 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 ...

Page 55: ... 5 5 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 U2D21AE0 book Page 5 Monday June 26 2006 2 18 PM ...

Page 56: ...LATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SE...

Page 57: ...WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U2D21AE0 book Page 2 Monday June 26 2006 2 18 PM ...

Page 58: ... plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system Check for leakage Tigh...

Page 59: ...utch Check operation fluid level and for fluid leakage 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for...

Page 60: ...Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Centerstand and sidestand pivots Check operation Apply lithium soap based grease all purpose grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leak age Replace if necessary 17 Shock absorber as sembly Check operation and for oil leak ...

Page 61: ...month and thereafter every 16000 mi 25000 km or 24 months Change Change 23 Front and rear brake switches Check operation 24 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 25 Throttle 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 No ITEM ROUTINE INITIAL ODOMET...

Page 62: ...tch release cylinder always change the fluid Regularly check the brake and YCC S clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or YCC S clutch master cylinders caliper cylinders and YCC S clutch release cylinder every two years Replace the brake and YCC S clutch hoses every four years or if cracked or damaged 26 Lights signals and swi...

Page 63: ...0 Panel A To 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 16 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 ...

Page 64: ... C To remove the panel 1 Remove the seats See page 3 16 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 U2D21AE0 book Page 9 Monday June 26 2006 2 18 ...

Page 65: ...could be operating 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 t...

Page 66: ... 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 it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side...

Page 67: ...r wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 6 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 1 Engine oil filler cap 2 Oil filter cartridge 3 Engine oil drain bolt 1 Oil filter cartridge 2 Oi...

Page 68: ...gine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer chec...

Page 69: ...oil level should be at the brim of the filler hole 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it to the specified torque To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to dr...

Page 70: ...eriodic mainte nance and lubrication chart 1 Place the vehicle on the center stand NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the 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 sho...

Page 71: ...heck the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 34 for further instructions EAU33030 Changing th...

Page 72: ...e 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 speci...

Page 73: ...s that can shift Securely 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 no...

Page 74: ...nal knowl edge and experience Tire information 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 ma...

Page 75: ...ion of your vehicle note the following points regarding the specified wheels The 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 ...

Page 76: ...chase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha EAU40620 YCC S clutch This model is equipped with a hydraulic clut...

Page 77: ...ront brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check ...

Page 78: ...e 6 8 The YCC S clutch fluid reservoir is located behind panel B See page 6 8 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 fl...

Page 79: ...he 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 EAU23090 Checking and lubricating th...

Page 80: ...le should be 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 U2D21AE0 book Page 25 Monday June 26 2006 2 18 PM ...

Page 81: ...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 Lithium soap based grease ...

Page 82: ...dition 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 brake push down hard on the handlebars several times to check if the front fork compresses and rebounds sm...

Page 83: ...ly 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...

Page 84: ... a physician 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 mon...

Page 85: ...rn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Fuse box 3 ABS motor fuse 4 ABS motor spare fuse 1 Fuse box 2 Right radiator fan fuse 3 Left radiator fan fuse 4 Hazard fuse 5 Backup fuse for odometer and clock 6 YCC S motor control fuse 7 Headlight fuse 8 Signaling system fuse 9 ABS contro...

Page 86: ...n 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 control unit f...

Page 87: ...e passenger seat See page 3 16 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 sock...

Page 88: ...rouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience ...

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

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

Page 91: ...leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts...

Page 92: ...on After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome an...

Page 93: ...ction of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs an...

Page 94: ...ry month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the ba...

Page 95: ...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 gal Fu...

Page 96: ... 459 lb U49 Front 270 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 Ope...

Page 97: ...tral indicator 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 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 Auxi...

Page 98: ...entification number The key identification 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...

Page 99: ...is affixed to the frame under the passenger seat See page 3 16 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer 1 Model label U2D21AE0 book Page 2 Monday June 26 2006 2 18 PM ...

Page 100: ...estigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tr...

Page 101: ...icle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc E...

Page 102: ...inder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km ...

Page 103: ...FORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U2D21AE0 book Page 6 Monday June 26 2006 2 18 PM ...

Page 104: ...CONSUMER INFORMATION 9 7 9 EAU26662 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U2D21AE0 book Page 7 Monday June 26 2006 2 18 PM ...

Page 105: ...CONSUMER INFORMATION 9 8 9 U2D21AE0 book Page 8 Monday June 26 2006 2 18 PM ...

Page 106: ...ed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing...

Page 107: ...ked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U2D21AE0 book Page 10 Monday June 26 2006 2 18 PM ...

Page 108: ... H Handlebar position adjusting 3 21 Handlebar switches 3 10 Hand shift control switch 3 11 Hand shift lever 3 13 Hazard switch 3 11 Headlight beams adjusting 3 21 Headlight bulb 6 31 High beam indicator light 3 3 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 27 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate...

Page 109: ...6 25 Tires 6 18 Tool kit 6 1 Troubleshooting 6 33 Troubleshooting charts 6 34 Turn signal indicator lights 3 2 Turn signal light or tail brake light bulb replacing 6 32 Turn signal switch 3 10 V Valve clearance 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 28 Wheels 6 20 Windshield position adjusting switch 3 11 Y YCC S clutch 6 21 YC...

Page 110: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 111: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 112: ...PRINTED IN JAPAN 2006 07 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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