Yamaha FJR13AV(C) Owner'S Manual Download Page 80

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-28

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.

EAU23140

Checking and lubricating the
brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-pur-
pose grease)

U3P610E0.book Page 28 Thursday, December 22, 2005 11:16 AM

Summary of Contents for FJR13AV(C)

Page 1: ...3P6 28199 10 FJR13AV C OWNER S MANUAL LIT 11626 19 83 ...

Page 2: ...EAU10041 U3P610E0 book Page 1 Thursday December 22 2005 11 16 AM ...

Page 3: ...cle 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 stan...

Page 4: ...nsult 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 WARN...

Page 5: ...HNIQUES 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 U3P610E0 book Page 2 Thursday December 22 2005 11 16 AM ...

Page 6: ...on U S A 1st edition December 2005 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 83 AFFIX DEALER LABEL HERE U3P610E0 book Page 3 Thursday December 22 2005 11 16 AM ...

Page 7: ... Shifting 5 2 Engine break in 5 3 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 11 Canister for California only 6 12 Engine oil and oil filter cartridge 6 13 Final gear oil 6 ...

Page 8: ...l brake light bulb 6 36 Replacing the license plate light bulb 6 37 Troubleshooting 6 37 Troubleshooting charts 6 38 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 LIMITED WARRANT...

Page 9: ... 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 motor...

Page 10: ...ld 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 exh...

Page 11: ...aution 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 sus...

Page 12: ...uate 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 fal...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3P610E0 book Page 5 Thursday December 22 2005 11 16 AM ...

Page 14: ...ETY INFORMATION 1 6 1 1 California only 2 California only 5 1 kg 2 lbs 4BR 24877 A0 LOAD LIMIT 4 3 kg 7 lbs 3TB 24877 A0 LOAD LIMIT 3 California only U3P610E0 book Page 6 Thursday December 22 2005 11 16 AM ...

Page 15: ...e 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 U3P610E0 book Page 7 Thursday December 22 2005 11 16 AM ...

Page 16: ...at page 3 14 6 Passenger seat page 3 14 7 Final gear oil filler bolt page 6 15 8 Final gear oil drain bolt page 6 15 9 Shock absorber assembly spring preload adjusting lever page 3 23 10 Air filter element page 6 18 11 Shift pedal page 3 11 12 Engine oil filler cap page 6 13 13 Engine oil filter cartridge page 6 13 14 Engine oil level check window page 6 13 U3P610E0 book Page 1 Thursday December 2...

Page 17: ... Windshield page 3 8 5 Battery page 6 32 6 Main fuse page 6 33 7 Front fork compression damping force adjusting screw page 3 21 8 Brake pedal page 3 11 9 Shock absorber assembly rebound damping force adjusting knob page 3 23 10 Rear brake fluid reservoir page 6 25 U3P610E0 book Page 2 Thursday December 22 2005 11 16 AM ...

Page 18: ...ervoir page 6 25 5 Tachometer page 3 3 6 Speedometer page 3 3 7 Multi function display page 3 4 8 Front brake fluid reservoir page 6 25 9 Right handlebar switches page 3 8 10 Brake lever page 3 11 11 Throttle grip page 6 20 12 Main switch steering lock page 3 1 13 Headlight beam adjusting knob page 3 19 U3P610E0 book Page 3 Thursday December 22 2005 11 16 AM ...

Page 19: ... 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 lock the steering 1 Turn the handlebars all the way to the left or right 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key into the main switch and then turn ...

Page 20: ... trouble warning light This 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 4 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...

Page 21: ...ometer needle will sweep once across the speed range and then return to zero in order to test the electrical cir cuit EAU11872 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri ca...

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

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

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

Page 25: ...el consumption mode This display shows the distance that can be traveled on 1 0 US gal of fuel under the current riding conditions NOTE If traveling at speeds under 10 km h 6 0 mi h _ _ will be displayed Average fuel consumption mode This display shows the average fuel consumption since it was last reset When the average fuel consumption mode is selected the display flashes for five seconds and th...

Page 26: ...those circuits are defective the multi function display will indicate a two digit error code e g 11 12 13 If the multi function display indicates such an error code note the code num ber and then have a Yamaha dealer check the vehicle CAUTION ECA11790 If the multi function display indi cates an error code the vehicle should be checked as soon as pos sible in order to avoid engine dam age EAU12344 ...

Page 27: ...on 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 engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions...

Page 28: ...peration 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 appropriate setting on the adjusting dial is aligned with the arrow mark on the clutch lever The clutch lever is equipped with a clutch switch w...

Page 29: ...d the handlebar 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 portio...

Page 30: ...lsating 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 fuel...

Page 31: ... 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 Yamaha ...

Page 32: ...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 Do no...

Page 33: ...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 16 1 Projection 2 Seat holder 1 Rider seat lock lever 2 Rider seat 1 Projection...

Page 34: ...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 35: ...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 36: ...rage compart ment B Do not exceed the maximum load of 211 kg 465 lb CAL 212 kg 467 lb U49 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 acce...

Page 37: ... lower the height 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 Handleb...

Page 38: ...to the 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 U3...

Page 39: ...g screws 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 appro...

Page 40: ...tings NOTE 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 specifica...

Page 41: ...ften the 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...

Page 42: ...ions See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to as...

Page 43: ...revents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed on the centerstand during this in spect...

Page 44: ...the engine 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 shou...

Page 45: ...gine 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 18 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 circuit...

Page 46: ...ences 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 wor...

Page 47: ...leed 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 25 6 25 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 b...

Page 48: ...on is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and sw...

Page 49: ...clutch lever pulled and the sid estand up WARNING 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 25 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15500 The following warning lights should come on for a few seconds then go off Oil l...

Page 50: ... 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 transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which...

Page 51: ...light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below 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 material carefully Since the engine is brand new do not put an exc...

Page 52: ...r during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and 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 overt...

Page 53: ...D 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 SER VI...

Page 54: ...ING 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 U3P610E0 book Page 2 Thursday December 22 2005 11 16 AM ...

Page 55: ...ugs 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 Tighten...

Page 56: ...k operation and fluid leak age Correct if necessary 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 da...

Page 57: ...13 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 le...

Page 58: ...th 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 ODOMETER ...

Page 59: ...tch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged 26 Lights signals and switches Check operation Ad...

Page 60: ...el 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 EAU39562 Panel B To remove the panel 1 Open the accessory box lid See page 3 18 2 Remove the bolt screw and the quick fasteners shown and then take the panel off 1 Panel A 2 Panel B 3 Panel C 4 Panel D 1 Panel E 1 Pa...

Page 61: ... CAUTION ECA15420 Do not remove the headlight beam adjusting cable To install the panel 1 Place the panel in the original posi tion and then install the bolt and quick fastener 2 Install the panel EAU39582 Panel D To remove the panel 1 Remove panels B and C See page 6 8 2 Remove the bolts and quick fas tener shown and then remove the panel 1 Panel B 2 Bolt 3 Screw 4 Quick fastener 1 Panel C 2 Bolt...

Page 62: ...1 Panel E To remove the panel 1 Remove the seats See page 3 14 2 Remove the bolts and the quick fastener screws and then take the panel off To install the panel 1 Place the panel in the original posi tion and then install the bolts and the quick fastener screws 2 Install the seats 1 Panel D 2 Bolt 3 Quick fastener 1 Headlight beam adjusting cable 1 Panel D 1 Panel E 2 Bolt 3 Quick fastener screw U...

Page 63: ...ecked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark p...

Page 64: ... plug should be tightened to the speci fied torque as soon as possible EAU19681 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Make sure that the canister br...

Page 65: ...ow located 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 of...

Page 66: ...eck the 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...

Page 67: ...ers 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 final gear oil must be changed as follows ...

Page 68: ...se 3 Install 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 t...

Page 69: ...king 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 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 CAU...

Page 70: ...ructions 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 EAU20471 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintena...

Page 71: ...roperly 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 qu...

Page 72: ...ified in the periodic maintenance and lubrication chart EAU21750 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when th...

Page 73: ...ld cause tire damage an accident or even injury Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 ...

Page 74: ...Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Oth...

Page 75: ...in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you...

Page 76: ...lever free play does become excessive and shifting becomes rough or clutch slippage occurs causing poor acceler ation there may be air in the clutch sys tem If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motor cycle EAU36500 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjust...

Page 77: ...heck the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 0 8 mm 0 03 in have a Yamaha dealer replace the brake pads as a...

Page 78: ...me 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 negative pressure if the fluid level goes down too far Be sure to return the diaphragm to its original shape before installing it into the brake or clutch fluid reservoir Be careful that water or du...

Page 79: ...es and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible t...

Page 80: ...pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U3P610E0 book Page 28 Thursday December 22 2005 11 16 AM ...

Page 81: ... centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Rec...

Page 82: ...on 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 smooth...

Page 83: ...upport 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 ...

Page 84: ...hysician 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 r...

Page 85: ...ollows 1 Turn 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 Headlight fuse 7 Signaling system fuse 8 ABS control unit fuse 9 Ig...

Page 86: ...light bulb burns out replace it as follows 1 Remove panel D if replacing the left headlight bulb or panel C if re placing the right headlight bulb See page 6 8 2 Disconnect the headlight coupler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb Specified fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition f...

Page 87: ...he transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Install the headlight bulb ...

Page 88: ...ssenger seat See page 3 14 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...

Page 89: ...ble 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 and...

Page 90: ...ression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The...

Page 91: ...ssing 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 the ...

Page 92: ...ve 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 Be...

Page 93: ...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 and n...

Page 94: ...n 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 and th...

Page 95: ...onth 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 batter...

Page 96: ... 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 Fuel...

Page 97: ...7 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 Operat...

Page 98: ...hting LED Neutral 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 fus...

Page 99: ...fication 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 may...

Page 100: ...affixed to the frame under the passenger seat See page 3 14 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 U3P610E0 book Page 2 Thursday December 22 2005 11 16 AM ...

Page 101: ...gation 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 Transp...

Page 102: ...e 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 Exha...

Page 103: ...r 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 or 4...

Page 104: ...ATION 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 U3P610E0 book Page 6 Thursday December 22 2005 11 16 AM ...

Page 105: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U3P610E0 book Page 7 Thursday December 22 2005 11 16 AM ...

Page 106: ...CONSUMER INFORMATION 9 8 9 U3P610E0 book Page 8 Thursday December 22 2005 11 16 AM ...

Page 107: ...epairs 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 pho...

Page 108: ... 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 U3P610E0 book Page 10 Thursday December 22 2005 11 16 AM ...

Page 109: ...witch 3 9 Headlight beams adjusting 3 19 Headlight bulb replacing 6 34 High beam indicator light 3 2 Horn switch 3 9 I Identification numbers 9 1 Ignition circuit cut off system 3 25 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 37 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance em...

Page 110: ...hooting charts 6 38 Turn signal indicator lights 3 2 Turn signal light or tail brake light bulb replacing 6 36 Turn signal switch 3 9 V Valve clearance 6 20 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheels 6 23 Windshield position adjusting switch 3 9 U3P610E0 book Page 2 Thursday January 12 2006 1 31 PM ...

Page 111: ...PRINTED IN JAPAN 2006 01 1 7 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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