Yamaha FJR13AY(C) Owner'S Manual Download Page 54 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-2

7

EAU17361

Owner’s tool kit

The owner’s tool kit is located under the
rider seat. (See page 4-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

1. Owner’s tool kit

U3P613E0.book Page 2 Friday, September 12, 2008 9:28 AM

PartShark.com

877-999-5686

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Summary of Contents for FJR13AY(C)

Page 1: ...DIC183 3P6 28199 13 FJR13AY C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 22 73 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U3P613E0 book Page 1 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 3: ...rds it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancies between your motorcyc...

Page 4: ...that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U3P613E0 book Page 1 Friday September 12 2008...

Page 5: ...st edition September 2008 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 22 73 U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 6: ...ng 6 2 Engine break in 6 3 Parking 6 4 PERIODIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing panels 7 8 Checking the spark plugs 7 13 Canister for California only 7 14 Engine oil and oil filter cartridge 7 14 Final gear oil 7 17 Coolant 7 18 Cleaning the air f...

Page 7: ...license plate light bulb 7 37 Troubleshooting 7 38 Troubleshooting charts 7 39 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YA...

Page 8: ...mportant information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer U3P613E0 book Page 1 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 9: ...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 U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 10: ... 42psi 270 kPa 2 70 kgf cm2 39psi 290 kPa 2 90 kgf cm2 42psi 3P6 21668 00 NOTICE Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 4B5 2815K 00 U3P613E0 book Page 3 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 11: ... motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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...

Page 12: ...rment 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 Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem b...

Page 13: ... both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never...

Page 14: ...ability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross wi...

Page 15: ...ger seat page 4 16 7 Final gear oil filler bolt page 7 17 8 Final gear oil drain bolt page 7 17 9 Shock absorber assembly spring preload adjusting lever page 4 24 10 Air filter element page 7 20 11 Shift pedal page 4 11 12 Engine oil filler cap page 7 14 13 Engine oil filter cartridge page 7 14 14 Engine oil level check window page 7 14 U3P613E0 book Page 1 Friday September 12 2008 9 28 AM P a r t...

Page 16: ...5 Battery page 7 32 6 Main fuse page 7 34 7 Front fork compression damping force adjusting screw page 4 22 8 Brake pedal page 4 12 9 Shock absorber assembly rebound damping force adjusting knob page 4 24 10 Rear brake fluid reservoir page 7 26 U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 17: ...chometer page 4 4 6 Speedometer page 4 3 7 Multi function display page 4 4 8 Front brake fluid reservoir page 7 26 9 Right handlebar switches page 4 9 10 Brake lever page 4 11 11 Throttle grip page 7 21 12 Main switch steering lock page 4 1 13 Headlight beam adjusting knob page 4 20 U3P613E0 book Page 3 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 18: ...on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF 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 EAU10691 LOCK The steering is locked and all electrical systems are off The key can be re...

Page 19: ... light This warning light comes on if the en gine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit TIP Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or dece...

Page 20: ...possible See page 4 12 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 the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be chec...

Page 21: ...an distract the operator and increase the risk of an accident The multi function display is equipped with the following an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled on the fuel reserve a clock a fuel meter a coolant temperature meter a transmission gea...

Page 22: ...rip F the display flashes for five seconds To reset a tripmeter select it by push ing the select button and then push the select button for at least one second while the display is flashing If you do not reset the fuel reserve tripmeter manually it will reset itself automatical ly and the display will return to the prior mode after refueling and traveling 5 km 3 mi Clock To set the clock 1 Push th...

Page 23: ...ture meter With the key in the ON position the coolant temperature meter indicates the temperature of the coolant When the key is turned to ON all of the dis play segments of the coolant tempera ture meter will appear one after the other and then disappear in order to test the electrical circuit The coolant temperature varies with changes in the weather and engine load If the top seg ment flashes ...

Page 24: ...ature than 16 F will not be displayed If the ambient temperature climbs above 122 F a higher tempera ture than 122 F will not be dis played The accuracy of the temperature reading may be affected when riding slowly approximately under 20 km h 12 5 mi h or when stopped at traffic signals railroad crossings etc Instantaneous fuel consumption mode This display shows the distance that can be traveled ...

Page 25: ...eled 1 km 0 6 mi NOTICE ECA15472 If there is a malfunction will be displayed Have a Yamaha dealer check the vehicle Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the multi function dis play will indicate a two digit error code If the mult...

Page 26: ...o the center position EAU12493 Windshield position adjusting switch To move the windshield up push this switch in direction a To move the windshield down push the switch in di rection b TIP When the key is turned to OFF the windshield will automatically return to the lowest position EAU12500 Horn switch Press this switch to sound the horn 1 Windshield position adjusting switch 2 Dimmer switch 3 Tu...

Page 27: ... of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard NOTICE ECA10061 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12830 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage...

Page 28: ... EAU26823 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate ...

Page 29: ...no sis test for a few seconds each time the vehicle first starts off after the main switch was turned on During this test a clicking noise can be heard 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 pulsat...

Page 30: ... lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover TIP The fuel tank cap cannot be closed 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 EWA11091 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Front wheel hub 1 Rear w...

Page 31: ... surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water...

Page 32: ...rs in the exhaust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any mainte...

Page 33: ... 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 it in place 1 Passenger ...

Page 34: ...ght 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 4 16 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 mark 1 Low position 2 High...

Page 35: ... 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 seat holder cover 1 H p...

Page 36: ...tments Storage compartment A is located un der the rider seat See page 4 16 Storage compartment B is located un der the passenger seat See page 4 16 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 FJR13AY 212 kg 467 lb FJR13AYC 211 kg 465 lb for the vehicle 1...

Page 37: ... 0 3 kg 0 66 lb for the accessory box Do not exceed the maximum load of FJR13AY 212 kg 467 lb FJR13AYC 211 kg 465 lb for the vehicle 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 drivers when carry ing ...

Page 38: ...s 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 U3P613E0 book Page 21 Frid...

Page 39: ...ginal position before riding EAU14732 Adjusting the front fork WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting knobs and compres sion damping force adjusting screws NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn bey...

Page 40: ... damping force and thereby harden the compres sion 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 kno...

Page 41: ...djust ing lever and a rebound damping force adjusting knob NOTICE ECA16570 To avoid damaging the mechanism do not attempt to move 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 tion a Rebound damping force To increase the rebound damping force a...

Page 42: ...ny service 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 TIP 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 mus...

Page 43: ...hen the trans mission is in gear and the side stand is up but 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 follow...

Page 44: ...Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The mo...

Page 45: ...his vehicle is equipped with an auxilia ry DC jack in the accessory box A 12 V accessory connected to the auxiliary jack can be used when the key is in the ON position and should only be used when the engine is running To use the auxiliary DC jack 1 Open the accessory box lid See page 4 20 2 Turn the key to OFF 3 Remove the auxiliary DC jack cap 4 Insert the accessory plug into the auxiliary DC ja...

Page 46: ...owing points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 14 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 14 Final gear oil Check vehicle for oil leakage 7 17 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooli...

Page 47: ...ave Yamaha dealer adjust cable free play and lubricate cable and grip housing 7 21 7 28 Control cables Make sure that operation is smooth Lubricate if necessary 7 28 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 22 7 24 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 28 Brake...

Page 48: ...k operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 25 ITEM CHECKS PAGE U3P613E0 book Page 3 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 49: ...gine stops automatically if left idling for 20 minutes In this case the multi function display indicates error code 70 but this is not a mal function Push the start switch to clear the error code and to restart the engine EAU40283 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 is in the neutral po...

Page 50: ...on TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE 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 ...

Page 51: ...t 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 excessive load on it for the first 1600 km 1000 m...

Page 52: ... the vehi cle EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 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 and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park ...

Page 53: ... parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleaner air but are also vital to proper engine operation and ...

Page 54: ... intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S...

Page 55: ...just 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 if necessary Replace ...

Page 56: ...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 dam age Replace if neces...

Page 57: ... 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 READINGS 600 mi 1000 km ...

Page 58: ...e 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 26 Control cables Apply Yamaha chain and cable lube or engine oil thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 ...

Page 59: ...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 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing an...

Page 60: ...nd 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 4 20 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 Bol...

Page 61: ...le ECA15421 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 EAU39583 Panel D To remove the panel 1 Remove panels B and C See page 7 8 2 Remove the bolts and quick fas tener shown and then remove the panel NOTICE Do not remove the headlight beam adjusting cable ECA15421 1 Panel B 2 Bolt 3 Screw 4 Quick fastener 1 Pane...

Page 62: ...7050 Panels E and F To remove one of the panels 1 Remove the seats See page 4 16 2 Remove the bolts and the quick fastener screws 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 U3P613E0 book Page 10 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 63: ... release it in the rear as shown To install the panel 1 Insert the rear of the panel into the rear cowling as shown and then insert the top edge of the panel into the fuel tank side cover 1 Panel E 1 Panel E 1 1 1 Panel E 1 Panel F 1 1 1 Panel F 1 Panel F 1 1 U3P613E0 book Page 11 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 64: ... and the quick fas tener screws 4 Install the seats 1 Panel E 2 Rear cowling 1 Panel E 2 Fuel tank side cover 1 2 1 2 1 Panel E 1 Panel F 2 Rear cowling 1 1 2 1 Panel F 2 Fuel tank side cover 1 Panel F 1 2 1 U3P613E0 book Page 12 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 65: ...perly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and ...

Page 66: ...hicle on the center stand 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 of the crank case TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is bel...

Page 67: ...a dealer 6 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 7 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 Oil filter wrench 1 O ring 1 Oil filter cartridge 2 Torq...

Page 68: ... mate rial enters the crankcase 10 Start the engine 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 TIP After the engine is started the engine oil level warning light should go off if the oil level is sufficient NOTICE ECA10400 If the oil level warning light flickers or remains on immediately turn...

Page 69: ...r oil level 1 Place the vehicle on the center stand TIP The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the final gear oil filler bolt and then check the oil level in the final gear case TIP The oil level should be at the brim of the filler ho...

Page 70: ...ed in the periodic maintenance and lubrication chart EAU40153 To check the coolant level 1 Place the vehicle on the center stand TIP 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 i...

Page 71: ...ossible other wise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 EAU33031 Changing the coolant The coolant must be changed at the in tervals specified in the periodic mainte nance and ...

Page 72: ...most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 6 Insert the air filter element into the air filter case NOTICE Make sure that the air filter element is prop erly 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 cylind...

Page 73: ...cted by a Yamaha dealer EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 1 Fuel tank breather overflow hose Engine idling speed 1000 1100 r min 1 Throttle cable free play U3P613E0 book Page 21 Friday September 12 20...

Page 74: ...e must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire air pres...

Page 75: ...rmation This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10481 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle may be different which could lead to an accident Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve c...

Page 76: ... 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 replaced An unbalanced wheel...

Page 77: ...ight which is activated by the brake pedal should come on just before braking takes effect If neces sary have a Yamaha dealer adjust the brake light switch EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU43431 Front brake pads The front brake calipers are equipped...

Page 78: ...luid may allow air to enter the brake or clutch systems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage TIP The rear bra...

Page 79: ...ling point of the fluid and may result in vapor lock and dirt may clog the ABS hy draulic unit valves Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22751 Changing...

Page 80: ...ace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion 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 bra...

Page 81: ...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 Recommended lubricant Silicone grease U3P613E0 book Page 29 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 82: ...and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control 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 Rec...

Page 83: ...r 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 WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly NOTICE ECA105...

Page 84: ...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 EAU39524 Battery The battery is located under panel A See page 7 8 This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check t...

Page 85: ...520 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a con stant voltage battery charger have a Yamaha dealer charge your battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and the...

Page 86: ...ox 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 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 25 0 A Signaling system ...

Page 87: ...spar 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 1 Remove panel D if replacing the le...

Page 88: ...al circuit or replace the bulb EAU27003 Replacing a rear turn signal light bulb or a tail brake light bulb 1 Remove the passenger seat See page 4 16 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the burnt out 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 Instal...

Page 89: ...ether with the bulb by pulling it out 3 Remove the burnt out 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 U3P613E0 book Page 37 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5...

Page 90: ...t to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and make sure there are no ...

Page 91: ...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 engine turns over quickly The engine turns over slowly Th...

Page 92: ...p while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha deal...

Page 93: ...h plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and de greaser off w...

Page 94: ...mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area 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 corro...

Page 95: ...m with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26242 Storage Short term Always store your motorcycle in...

Page 96: ...l the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in...

Page 97: ...nal 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 6 61 US gal 5 50...

Page 98: ...FJR13AYC 90 211 kg 198 465 lb Front 270 kPa 2 70 kgf cm 39 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 270 kPa 2 70 kgf cm 39 psi Rear 290 kPa 2 90 kgf cm 42 psi 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 Sin...

Page 99: ...tor 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 ABS solenoid fu...

Page 100: ... 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 TIP The vehicle identification number is used to identify your motorcycle and may be used to register...

Page 101: ... under the passenger seat See page 4 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 U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 102: ...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 Seventh Street SW Washington...

Page 103: ... 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 Exhaust system Muffler E...

Page 104: ...ork 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 42 months 32000 mi 49...

Page 105: ... 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U3P613E0 book Page 6 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 106: ...ized 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 motorcycle covered by t...

Page 107: ...a 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 warranty service you must ...

Page 108: ...ductible 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 phone calls even food a...

Page 109: ...er 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 U3P613E0 book Page 10 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 110: ...dlight beams adjusting 4 20 Headlight bulb replacing 7 35 High beam indicator light 4 2 Horn switch 4 9 I Identification numbers 10 1 Ignition circuit cut off system 4 26 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 37 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control...

Page 111: ...indicator lights 4 2 Turn signal light or tail brake light bulb replacing 7 36 Turn signal switch 4 9 V Valve clearance 7 22 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 32 Wheels 7 24 Windshield position adjusting switch 4 9 U3P613E0 book Page 2 Friday September 12 2008 9 28 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 112: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 113: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 114: ...PRINTED IN JAPAN 2008 09 0 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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