Yamaha FJR13AX(C) Page 60 Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

EAU18771

Removing and installing pan-
els

The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

EAU39550

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.

EAU39562

Panel B

To remove the panel

1. Open the accessory box lid. (See

page 3-19.)

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. Panel F

1. Panel A
2. Bolt

3. Quick fastener

U3P612E0.book Page 8 Tuesday, October 16, 2007 9:14 AM

Summary of Contents for FJR13AX(C)

Page 1: ...3P6 28199 12 FJR13AX C OWNER S MANUAL LIT 11626 21 63 ...

Page 2: ...EAU10041 U3P612E0 book Page 1 Tuesday October 16 2007 9 14 AM ...

Page 3: ...cycle 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 st...

Page 4: ...onsult 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 WAR...

Page 5: ...ECHNIQUES 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 U3P612E0 book Page 2 Tuesday October 16 2007 9 14 AM ...

Page 6: ...tion U S A 1st edition October 2007 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 21 63 AFFIX DEALER LABEL HERE U3P612E0 book Page 3 Tuesday October 16 2007 9 14 AM ...

Page 7: ...ine 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 11 Canister for California only 6 12 Engine oil and oil filter cartridge 6 12 Final gear...

Page 8: ...r a tail brake light bulb 6 36 Replacing the license plate light bulb 6 37 Troubleshooting 6 38 Troubleshooting charts 6 39 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 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND EN...

Page 9: ...ts 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 mot...

Page 10: ...eld 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 ex...

Page 11: ... 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 s...

Page 12: ...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 f...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3P612E0 book Page 5 Tuesday October 16 2007 9 14 AM ...

Page 14: ...ORMATION 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 PRESS REGULATOR U3P612E0 book Page 6 Tuesday October 16 2007 9 14 AM ...

Page 15: ...ine 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 U3P612E0 book Page 7 Tuesday October 16 2007 9 14 AM ...

Page 16: ...seat page 3 15 6 Passenger seat page 3 15 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 12 13 Engine oil filter cartridge page 6 12 14 Engine oil level check window page 6 12 U3P612E0 book Page 1 Tuesday October 1...

Page 17: ...4 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 26 U3P612E0 book Page 2 Tuesday October 16 2007 9 14 AM ...

Page 18: ...eservoir page 6 26 5 Tachometer page 3 3 6 Speedometer page 3 3 7 Multi function display page 3 4 8 Front brake fluid reservoir page 6 26 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 U3P612E0 book Page 3 Tuesday October 16 2007 9 14 AM ...

Page 19: ...l 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: ...ne 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 8 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 th...

Page 21: ...edometer 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 ...

Page 22: ...instan 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: ...the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT 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...

Page 24: ...age 6 39 CAUTION ECA10020 Do not operate 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 Ai...

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 ...

Page 26: ...defective the engine trouble warning light will come on and then the multi function display will indicate a two digit error code 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 e...

Page 27: ... 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 prior to starti...

Page 28: ... 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 appropriate setting on the adjusting dial is aligned with the arrow mark ...

Page 29: ...ver 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 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 ...

Page 30: ...ard from under the seat and if the brake lever or brake ped al are even slightly applied a vi bration can be felt at the lever and pedal but these do not indicate a malfunction When the ABS is activated the brakes are operated in the usual way A pulsating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner t...

Page 31: ...sed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler tu...

Page 32: ...ohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13442 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the e...

Page 33: ...f the seat down to lock it in place 2 Remove the key Rider seat To remove the rider seat 1 Remove the passenger seat 2 Push the rider seat lock lever lo cated under the back of the rider seat to the left as shown and then pull the seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock i...

Page 34: ...ence The rider seat height was adjusted to the lower position at delivery To change the rider seat height to the high position 1 Remove the rider seat See page 3 15 2 Remove the rider seat height posi tion adjuster by pulling it upward 3 Move the rider seat holder cover to the lower position as shown 4 Install the rider seat height position adjuster so that the H mark is aligned with the match mar...

Page 35: ...ght posi tion adjuster by pulling it upward 3 Move the rider seat holder cover to the upper position 4 Install the rider seat height position adjuster so that the L mark is aligned with the match mark 5 Insert the projection on the front of the rider seat into seat holder A as shown 1 Rider seat height position adjuster 2 H mark 3 Match mark 1 Projection 2 Seat holder B for high position 3 Rider s...

Page 36: ...ed with two stor age compartments Storage compartment A is located un der the rider seat See page 3 15 Storage compartment B is located un der the passenger seat See page 3 15 WARNING EWA14420 Do not exceed the load limit of 1 kg 2 lb for storage compart ment A Do not exceed the load limit of 3 kg 7 lb for storage compart ment B Do not exceed the maximum load of 211 kg 465 lb CAL 212 kg 467 lb U49...

Page 37: ...ot exceed the load limit of 0 3 kg 0 66 lb for the accessory box Do not exceed the maximum load of 211 kg 465 lb CAL 212 kg 467 lb U49 for the ve hicle EAU39611 Adjusting the headlight beams The headlight beam adjusting knobs are used to raise or lower the height of the headlight beams It may be neces sary to adjust the headlight beams to increase visibility and help prevent blinding oncoming driv...

Page 38: ... cowl ings The cowlings can be tilted back 30 mm 1 18 in for added ventilation to suit the riding conditions To open a cowling 1 Remove the quick fastener screws 2 Pull the cowling to the open posi tion and then install the quick fas tener screws To close a cowling 1 Remove the quick fastener screws 1 Handlebar 1 Closed position 2 Open position 3 Cowling 1 Quick fastener screw 1 Open position U3P6...

Page 39: ...original position before riding EAU14731 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting knobs and compres sion damping force adjusting 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 su...

Page 40: ...n damping turn the adjusting screw on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b 1 Current setting 2 Front fork cap bolt Spring preload setting Minimum soft 6 Standard 4 Maximum hard 1 1 Rebound damping force adjusting knob Rebound damping setting Minimum soft 17 click s...

Page 41: ...rber assembly This shock absorber assembly is equipped with a spring preload adjust ing lever and a rebound damping force adjusting knob CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload For riding solo move the spring preload adjusting lever in direction b For riding with a passenger move the spring preload adjusting lever in direc...

Page 42: ...tand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations 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 no...

Page 43: ... the clutch lever is not pulled It prevents 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 ...

Page 44: ...and down Does the engine stall After 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 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 be ridden until check...

Page 45: ...ngine 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 19 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 circui...

Page 46: ...uences 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 wo...

Page 47: ...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 25 6 26 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 ...

Page 48: ...tion 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 29 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 ...

Page 49: ...e engine in case of a turnover To start the engine after a turnover be sure to turn the main switch to OFF and then to ON Fail ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAU40281 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission ...

Page 50: ...n Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climb...

Page 51: ...o second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear...

Page 52: ... r min CAUTION ECA10331 After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the 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 ...

Page 53: ...TED 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 ...

Page 54: ...RNING 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 U3P612E0 book Page 2 Tuesday October 16 2007 9 14 AM ...

Page 55: ...lugs 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 Tighte...

Page 56: ...ck 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 d...

Page 57: ...licone grease lightly 13 Brake pedal pivot shaft Apply lithium soap based grease lightly 14 Clutch lever pivot shaft Apply silicone grease lightly 15 Shift pedal pivot shaft Apply lithium soap based grease lightly 16 Centerstand and sidestand pivots Check operation Apply lithium soap based grease lightly 17 Sidestand switch Check operation and replace if necessary No ITEM ROUTINE INITIAL ODOMETER ...

Page 58: ...for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 24 Final gear oil Check oil level and for leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 25 Front and rear brake switches Check operation No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7...

Page 59: ...equired 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 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttl...

Page 60: ...anel 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 19 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 ...

Page 61: ...el 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 Bo...

Page 62: ...ick fastener 2 Install panels B and C EAU39592 Panels E and F To remove one of the panels 1 Remove the seats See page 3 15 2 Remove the bolts and the quick fastener screws and then take the panel off 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 1 Panel F 2 Bolt 3 Quick fastener screw U3P612E0 book Page 10 Tuesday October 16 20...

Page 63: ...m to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon...

Page 64: ...d and if necessary clean it EAU19883 Engine oil and oil filter car tridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand NOTE Make sure that the vehicle is positioned s...

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

Page 66: ...ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 1 O ring 1 Oil filter cartridge 2 Torque wrench Tight...

Page 67: ...e 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 intervals specified in the periodic maintenance and lubrica tion chart WARNING EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or...

Page 68: ... from the final gear case 4 Install the final gear oil drain bolt and then tighten it to the specified torque 5 Refill with the recommended final gear oil to the brim of the filler hole 6 Install the oil filler bolt and then tighten it to the specified torque 7 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Final gear oil filler bolt 2 Final gear oil drain bolt 3...

Page 69: ...ng 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 coolant reservoir cap 4 Add coolant or distilled water to raise the coolant to the maximum level mark install the coolant res ervoir c...

Page 70: ...ging 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 maintenance and lubrication ch...

Page 71: ... properly 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 ...

Page 72: ...ottle 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...

Page 73: ...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 not ...

Page 74: ...l 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 make...

Page 75: ...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 repl...

Page 76: ... 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 EAU22072 Clutch lever Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is ...

Page 77: ...e equipped with two sets of brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check a brake pad for wear check its wear indicator groove If a brake pad has worn to the point that the wear indi cator groove has almost disappeared have a Yamaha dealer replace the brake pads as a set EAU225...

Page 78: ...e brake or 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 fro...

Page 79: ...h 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 EAU23091 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and ...

Page 80: ... the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease U3P612E0 book Page 28 Tuesday October 16 2007 9 14 AM ...

Page 81: ...king and lubricating the centerstand 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 Silicone grease Recommended lubric...

Page 82: ...be checked 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 ...

Page 83: ...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 Yamah...

Page 84: ...ind that 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 Fl...

Page 85: ...ttery leads 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 Yama...

Page 86: ...iately 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 and clock 6 ABS solenoid fuse 7 Fuel injection system fuse 8 Headlight fuse 9 Signaling system fuse 10 ABS control unit fuse 11 Ignition fuse 12 Auxiliary DC jack fuse 13 Spare fuse Specified fuses Main fuse 50 0 A Headlight fuse...

Page 87: ...d down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the 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 gerpr...

Page 88: ...U27001 Replacing a rear turn signal light bulb or a tail brake light bulb 1 Remove the passenger seat See page 3 15 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 bu...

Page 89: ...2 Remove 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 U3P612E0 book Page 37 Tuesday October 16 2007 9 14 AM ...

Page 90: ...roubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi ...

Page 91: ...There is 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 start...

Page 92: ...ed 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 cooling system for le...

Page 93: ...ler outlets 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 d...

Page 94: ...rea is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 ...

Page 95: ...duct Avoid 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 w...

Page 96: ...ground the 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...

Page 97: ...t 3 52 Imp qt Final gear oil Type 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 ...

Page 98: ...on 90 211 kg 198 465 lb CAL 90 212 kg 198 467 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 DO...

Page 99: ...W 1 Meter lighting 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 ...

Page 100: ...tification 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 m...

Page 101: ... affixed to the frame under the passenger seat See page 3 15 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 U3P612E0 book Page 2 Tuesday October 16 2007 9 14 AM ...

Page 102: ...nd 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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Sevent...

Page 103: ...le 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 Exh...

Page 104: ...der 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...

Page 105: ...RMATION 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 U3P612E0 book Page 6 Tuesday October 16 2007 9 14 AM ...

Page 106: ...warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha mo...

Page 107: ...later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warra...

Page 108: ... 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 p...

Page 109: ...d 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 U3P612E0 book Page 10 Tuesday October 16 2007 9 14 AM ...

Page 110: ...dlebar switches 3 8 Hazard switch 3 9 Headlight beams adjusting 3 19 Headlight bulb replacing 6 35 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...

Page 111: ...ing 6 38 Troubleshooting charts 6 39 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 32 Wheels 6 23 Windshield position adjusting switch 3 9 U3P612E0 book Page 2 Tuesday October 16 2007 9 14 AM ...

Page 112: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 113: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 114: ...PRINTED IN JAPAN 2007 10 1 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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