Yamaha MTN690-A 2019 Owner'S Manual Download Page 51 | Manualshive

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Periodic maintenance and adjustment

6-2

6

EAU17453

Tool kit

The tool kit is located inside the stor-
age compartment. (See page 3-22.)
The information included in this manual
and the tools provided in the tool kit are
intended to assist you in the perfor-
mance of preventive maintenance and
minor repairs. However, a torque
wrench and other tools are necessary
to perform certain maintenance work
correctly.

TIP

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

1. Tool kit

1

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Summary of Contents for MTN690-A 2019

Page 1: ...OWNER S MANUAL Read this manual carefully before operating this vehicle MTN690 A MTN690 U B7S F8199 30 ...

Page 2: ...this vehicle This manual should stay with this vehicle if it is sold EAU46091 EAU46091 䘉 অ䖖ԕࡽˈ䈧 ݵ 䘉ሿ Ǆ䘉享Ԉо অ䖖а䎧Ǆ EAU46091 Baca buku panduan dengan teliti sebelum mengendalikan motosikal ini Buku panduan diberi bersama dengan pembelian motosikal ...

Page 3: ... and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while thi...

Page 4: ... used to alert you to potential personal injury hazards Obey all safety messages 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 e...

Page 5: ...1 MTN690 A MTN690 U OWNER S MANUAL 2018 by Yamaha Motor Co Ltd 1st edition November 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...kit 6 2 Periodic maintenance charts 6 3 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Checking the spark plugs 6 8 Canister 6 9 Engine oil and oil filter cartridge 6 9 Coolant 6 12 Replacing the air filter element and cleaning the check hose 6 14 Checking the throttle grip free play 6 14 Valve clearance 6 15 Tires 6 15 Cast wheels 6 17...

Page 7: ...bulb 6 33 Replacing the license plate light bulb 6 34 Supporting the motorcycle 6 35 Troubleshooting 6 35 Troubleshooting charts 6 36 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 Diagnostic connector 9 2 Vehicle data recording 9 2 Index 10 1 ...

Page 8: ...raining courses nearest you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks t This motorcycle is designed to carry the operator and a passen ger t The failure of mo...

Page 9: ... rests during operation to main tain control of the motorcycle t The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests t Never ride under the influence of alcohol or other drugs t This motorcycle is designed...

Page 10: ...istribu tion of the motorcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas sen...

Page 11: ...d to your vehicle that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories t Never install accessories or carry cargo that would impair the per forman...

Page 12: ...and replacing your tires Transporting the Motorcycle Be sure to observe following instruc tions before transporting the motorcy cle in another vehicle t Remove all loose items from the motorcycle t Check that the fuel cock if equipped is in the off position and that there are no fuel leaks t Shift the transmission into gear for models with a manual trans mission t Secure the motorcycle with tie do...

Page 13: ...ool kit page 6 2 3 Storage compartment page 3 22 4 Rebound damping force adjuster page 3 23 5 Shift pedal page 3 14 6 Engine oil filler cap page 6 9 7 Engine oil drain bolt page 6 9 8 Engine oil level check window page 6 9 9 Engine oil filter cartridge page 6 9 10 Coolant reservoir page 6 12 ...

Page 14: ... EAU10421 Right view 3 5 2 1 6 7 4 1 Fuses page 6 29 2 Battery page 6 28 3 Spring preload adjuster page 3 23 4 Fuel tank cap page 3 16 5 Headlight page 6 31 6 Brake pedal page 3 14 7 Rear brake fluid reservoir page 6 20 ...

Page 15: ...7 8 1 Clutch lever page 3 13 2 Left handlebar switches page 3 12 3 Multi function meter unit page 3 6 4 Main switch steering lock page 3 2 5 Front brake fluid reservoir page 6 20 6 Right handlebar switches page 3 12 7 Throttle grip page 6 14 8 Brake lever page 3 14 ...

Page 16: ...CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either stan...

Page 17: ...bow keep it in a safe place and only use it for code re registering EAU36872 ON All electrical circuits are supplied with power The meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stall...

Page 18: ...g will not lock try turning the handlebars back to the right slight ly To unlock the steering From the LOCK position push the key in and turn it to OFF EAU59680 Parking The hazard lights and turn signal lights can be turned on but all other electri cal systems are off The key can be re moved The steering must be locked before the key can be turned to NOTICE ECA20760 Using the hazard or turn signal...

Page 19: ...If the warning light comes on when the engine is running stop the en gine immediately and check oil level If the oil level is below the minimum level add sufficient oil of the recom mended type to raise it up to the cor rect level If the oil pressure warning light remains on even if the oil level is correct immediately turn the en gine off and have a Yamaha dealer check the vehicle TIP If the warn...

Page 20: ...is turned to ON or if the warning light remains on have a Yamaha dealer check the vehicle EAU69891 ABS warning light In normal operation this warning light comes on when the key is turned to ON and goes off after traveling at a speed of 10 km h 6 mi h or higher If the ABS warning light t does not come on when the key is turned to ON t comes on or flashes while riding t does not go off after travel...

Page 21: ...tern have a Yamaha dealer check the vehicle TIP If the immobilizer system indicator light flashes in the pattern slowly 5 times then quickly 2 times this could be caused by transponder interference If this occurs try the following 1 Make sure there are no other im mobilizer keys close to the main switch Other immobilizer system keys may cause signal interfer ence and prevent the engine from starti...

Page 22: ...en displaying the clock the key must be turned to ON before you can use the left and right set buttons to adjust the multi function meter t For the UK To switch between ki lometers and miles press the left set button for three seconds Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal p...

Page 23: ...icates the amount of fuel in the fuel tank The segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the last segment of the fuel meter starts flashing refuel as soon as possible TIP The fuel meter is equipped with a self diagnosis function If a problem is de tected in the fuel meter electrical cir cuit the fuel meter will flash repeatedly If this occurs...

Page 24: ...tripmFtFrs TRIP 1 and TRIP 2 in stantanFPus fuFM DPnsumption km L or L 100 km BWFrBHF fuFM DPnsump tion AVE_ _ _ km L or AVE_ _ _ L 100 km DooMant tFmpFraturF _ _ C and air tFNpFSBturF Air_ _ C in thF foMMowing ordFr ODO o TRIP 1 o TRIP 2 o km L or L 100 km o AVE_ _ _ km L or AVE_ _ _ L 100 km o _ _ C o Air_ _ C o ODO For thF UK Push thF MFGt sFt button to DhangF thF dispMBZ bFtwFFn thF PEPNFtFS O...

Page 25: ...itch the display in the following order 53 1 F o km L or L 100 km o AVE_ _ _ km L or AVE_ _ _ L 100 km o _ _ C o Air_ _ o ODO o 53 1 1 o 53 1 2 o 53 1 F For the UK 53 1 F o km L L 100 km or M1G o AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ M1 o _ _ C o Air_ _ o ODO o 53 1 1 o 53 1 2 o 53 1 F TIP t 1ush the right set button to change the display in the reverse order t You can manually reset the fue...

Page 26: ..._ MPG for the UK The average distance that can be trav eled on 1 0 Imp gal of fuel is shown To switch the average fuel consump tion settings push and hold the left set button until the display changes To reset the average fuel consumption push and hold the right set button until the display changes TIP After resetting the average fuel con sumption _ _ _ will be shown until the vehicle has traveled...

Page 27: ...allows you to adjust the brightness level of the multi function meter unit To adjust the brightness 1 Turn the key to OFF 2 Push and hold the left set button 3 Turn the key to ON and continue pushing the left set button until the display switches to the brightness control mode 4 Push the right set button to set the brightness level 5 Push the left set button to confirm the selected brightness leve...

Page 28: ...gine Set this switch to to stop the en gine in case of an emergency such as when the vehicle overturns or when the throttle cable is stuck EAU12735 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped whe...

Page 29: ...ward the throttle grip The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip slightly pull the brake lever away from the throttle grip and rotate the adjusting dial Make sure the setting number on the adjust ing dial aligns with the match mark on the brake lever EAU12944 Brake pedal The brake pedal is located on ...

Page 30: ...S is monitored by an ECU which will revert the system to conven tional braking if a malfunction occurs TIP t The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a click ing noise can be heard from the hydraulic control unit and if the brake lever or brake pe...

Page 31: ... fuel Leaking fuel is a fire hazard EAU13222 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10882 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or whil...

Page 32: ...A11401 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 TIP t This mark identifies the recom mended fuel for this vehicle as specified by European regulation EN228 t Check that gasoline nozzle has the same identifier when fueling Your Yamaha engine has been de signed to use r...

Page 33: ...6871 Fuel tank overflow hose TIP See page 6 9 for breather hose infor mation Before operating the motorcycle t Check the fuel tank overflow hose connection t Check the fuel tank overflow hose for cracks or damage and replace it if necessary t Make sure that the end of the fuel tank overflow hose is not blocked and clean it if necessary t Make sure that the fuel tank over flow hose is routed throug...

Page 34: ... likely to touch the hot exhaust system t Make sure that the exhaust sys tem has cooled down before doing any maintenance work t Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10702 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU83850 Seats Passenger seat To remove the p...

Page 35: ...e seat 2 Remove the bolts with the hexa gon wrench 3 Lift the seat rearward and up to re move it To install the rider seat 1 Fit the slot in the seat onto the pro jection on the frame cross mem ber as shown and then place the seat in the original position 2 Install the bolts with the hexagon wrench 3 Insert the hexagon wrench back into its holder on the passenger seat 4 Install the passenger seat ...

Page 36: ...e through the buckle on the helmet strap 4 Hook the cable loops over the screwdriver install the screw driver by first inserting the screw driver into the holder with the mark and then slide the screw driver toward the holder with the mark TIP Make sure that the screwdriver is se curely positioned between its holders and then position the cable loops to ward the middle of the screwdriver be fore i...

Page 37: ... ble over the hook on the bottom of the passenger seat 4 Install the passenger seat EAU83880 Storage compartment The storage compartment is located as shown When storing documents wrap them in a plastic bag so they will not get wet When washing the vehicle avoid spraying water directly under the seat WARNING EWA10962 t Do not exceed the load limit of 1 5 kg 3 lb for the storage com partment t Do n...

Page 38: ...osition in dicator on the shock absorber t Use the special wrench and the extension bar included in the own er s tool kit to make the adjust ment Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in direction ...

Page 39: ... or attempt to open the cylinder assembly t Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure t Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance t Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorb...

Page 40: ...r 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 situa tions See the following section for an explanation of the ignition circuit cut off system WARNING EWA10242 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 otherw...

Page 41: ...m prevents in gear engine starts unless the clutch lever is pulled and the sidestand is up Also it will stop the running engine should the sidestand be lowered while the trans mission is in gear Periodically check the system via the following procedure TIP t This check is most reliable if per formed with a warmed up engine t See pages 3 2 and 3 12 for switch operation information ...

Page 42: ...ne stall After the engine has stalled 10 Move the sidestand up 11 Pull the clutch lever 12 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 The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working The motorcycle should not be ridden until checked by a...

Page 43: ...e following points E G A P S K C E H C M E T I Fuel t Check fuel level in fuel tank t Refuel if necessary t Check fuel line for leakage t Check fuel tank overflow hose for obstructions cracks or damage and check hose connection 3 16 3 18 Engine oil t Check oil level in engine t If necessary add recommended oil to specified level t Check vehicle for oil leakage 6 9 Coolant t Check coolant level in ...

Page 44: ...ealer adjust throttle grip free play and lubricate ca ble and grip housing 6 14 6 24 Control cables t Make sure that operation is smooth t Lubricate if necessary 6 24 Drive chain t Check chain slack t Adjust if necessary t Check chain condition t Lubricate if necessary 6 22 6 23 Wheels and tires t Check for damage t Check tire condition and tread depth t Check air pressure t Correct if necessary 6...

Page 45: ...ws are properly tightened t Tighten if necessary Instruments lights signals and switches t Check operation t Correct if necessary Sidestand switch t Check operation of ignition circuit cut off system t If system is not working correctly have Yamaha dealer check vehicle 3 25 E G A P S K C E H C M E T I ...

Page 46: ... when pushing the start switch t an engine auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU83331 Starting the engine Under normal conditions shift the transmission into neutral before start ing the engine To start the engine with the transmission in gear the sidestand must be up and the clutch l...

Page 47: ...s you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration 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 ECA10261 t Even with the transmission in the neutral position do not coast for lon...

Page 48: ... the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17094 0 1000 km 0 600 mi Avoid prolonged oper...

Page 49: ...312 t 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 t Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire t Do not park near grass or other flammable materials which might catch fire ...

Page 50: ...urn off the engine when performing maintenance unless otherwise specified t A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires t Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 3 for more in formation about carbon monox ide WARNING EWA1...

Page 51: ...ual and the tools provided in the tool kit are intended to assist you in the perfor mance of preventive maintenance and minor repairs However a torque wrench and other tools are necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have your Yamaha dealer perform it for you 1 Tool kit 1 ...

Page 52: ...emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line t Check fuel hoses for cracks or damage t Replace if necessary 2 Spark plugs t Check condition t Adjust gap and clean t Replace 3 Valve clearance i m 0 0 0 4 2 m k 0 0 0 0 4 y r e v E t s u j d a d n a k c e h C t 4...

Page 53: ...y r e v E e c a l p e R t 3 Air filter case check hose t Clean 4 Clutch t Check operation t Adjust 5 Front brake t Check operation fluid level and for fluid leakage t Replace brake pads if necessary 6 Rear brake t Check operation fluid level and for fluid leakage t Replace brake pads if necessary 7 Brake hoses t Check for cracks or damage s r a e y 4 y r e v E e c a l p e R t 8 Brake fluid s r a e...

Page 54: ...in or riding in wet areas 14 Steering bearings t Check bearing assemblies for looseness t Moderately repack with lithium soap based grease 15 Chassis fasteners t Make sure that all nuts bolts and screws are properly tightened 16 Brake lever pivot shaft t Lubricate with silicone grease 17 Brake pedal pivot shaft t Lubricate with lithium soap based grease 18 Clutch lever pivot shaft t Lubricate with...

Page 55: ...pension re lay arm and con necting arm pivoting points t Check operation 25 Engine oil t Change warm engine before draining t Check oil level and vehicle for oil leakage 26 Engine oil filter car tridge t Replace 27 Cooling system t Check coolant level and vehicle for coolant leakage s r a e y 3 y r e v E e g n a h C t 28 Front and rear brake switches t Check operation 29 Moving parts and cables t ...

Page 56: ... brake fluid level t Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid t Replace the brake hoses every four years and if cracked or damaged 30 Throttle grip hous ing and cable t Check operation and free play t Adjust the throttle cable free play if necessary t Lubricate the throttle grip housing and cable 31 Lights signals and swi...

Page 57: ...of elec trode 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 its mating surface and then wipe off any grime from the spark plug threads TIP If a torque wrench is not available when installing...

Page 58: ...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 a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false ...

Page 59: ...it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil filler cap 2 Engine oil level check win...

Page 60: ... parts after the engine and exhaust sys tem have cooled down NOTICE ECA11621 t 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 t Make sure that no foreign mate rial en...

Page 61: ...with distilled water at a 1 1 ratio EAU20097 To check the coolant level Since the coolant level varies with en gine temperature check when the en gine is cold 1 Park the vehicle on a level surface 1 Engine oil er cap 2 O ring 2 1 Recommended coolant YAMALUBE coolant Coolant quantity Coolant reservoir max level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 1 60 L 1 69 US qt 1 41 ...

Page 62: ... has been used instead of coolant replace it with cool ant as soon as possible 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 ECA10473 5 Install the coolant reservoir cap EAU33032 Cha...

Page 63: ...usty areas However the air filter check hose can be easily reached and should be frequently checked and cleaned if necessary To clean the air filter check hose 1 Remove the air filter check hose under the air filter case 2 Clean and then install the hose EAU21386 Checking the throttle grip free play Measure the throttle grip free play as shown Periodically check the throttle grip free play and if ...

Page 64: ...eplace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control t The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equal...

Page 65: ...d be left to a Yamaha dealer who has the necessary professional knowl edge and experience to do so t Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This model is equipped with tubeless tires and tire air valves Tires age even if they have not been used or have only been used occasion ally C...

Page 66: ...ly for approximately 100 km 60 mi after installing a new tire t The tires must be warmed up before a high speed run t Always adjust the tire air pres sure according to the operating conditions EAU21963 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels t The wheel rims should be checked for cracks bends wa...

Page 67: ...case 3 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in di rection b 4 Tighten the locknut EAU37914 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or sp...

Page 68: ...should only be serviced by a Yamaha dealer EAU22393 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 EAU36891 Front brake pads Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check t...

Page 69: ...e brake pads as a set EAU40262 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if necessary Front brake Rear brake WARNING EWA16011 Improper maintenance can result in loss of braking ability Observe these precautions t Insufficient brake fluid may al low...

Page 70: ...urfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause bef...

Page 71: ...l overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or break age If distance A is more than 58 0 mm 2 28 in the chain can damage the frame swingarm and other parts To prevent this from occurring keep the drive chain slack within the specified limits ECA23070 EAU59921 To adjust the drive chain slack Consult a Yamaha dealer before ad justing the drive ...

Page 72: ...therwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure ...

Page 73: ... as soon as possible to prevent unsafe condi tions EWA10712 EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is secur...

Page 74: ... before each ride and the pedal pivots should be lu bricated if necessary Brake pedal Shift pedal EAU23144 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease ...

Page 75: ...y have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAUM1653 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricants Brake lever Silicone grease Clutch lever ...

Page 76: ...d on the handle bars several times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23285 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in th...

Page 77: ...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 t EXTERNAL Flush with plenty of water t INTERNAL Drink large quan tities of water or milk and im mediately call a physician t EYES Flush with water for 15 minutes and seek pr...

Page 78: ...304 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure to turn the main switch off then con nect the positive lead before connecting the negative lead ECA16842 4 After installation make sure that the battery leads are properly con nected ...

Page 79: ...tes 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Backup fuse 2 for ECU 5 Backup fuse for clock and immobilizer sys tem 6 Radiator fan motor fuse 7 ABS solenoid fuse 8 ABS motor fuse 9 Parking lighting fuse 10 Auxiliary fuse 11 ABS control unit fuse 12 Spare fuse 7 8 9 10 11 1 2 3 4 5 6 12 12 Specif...

Page 80: ...e adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner t 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 the headlight unit by re moving the bolt and washer on each side 2 Disconnect the headlight coupler...

Page 81: ...a Yamaha dealer adjust the headlight beam if necessary EAU83660 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove the headlight unit See page 6 31 2 Remove the auxiliary light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pulling it out of the soc...

Page 82: ... Brake tail light This model is equipped with an LED type brake tail light If the brake tail light does not come on have a Yamaha dealer check it EAU24205 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 1 Auxiliary light bulb 1 1 Turn signal light lens 2 Screw 1 2 ...

Page 83: ...ght unit by removing the nuts washers and collars and then remove the license plate light bulb socket to gether with the bulb by pulling it out 2 Remove the burnt out bulb by pulling it out 3 Insert a new bulb into the socket 4 Install the socket together with the bulb by pushing it in and then install the license plate light unit by installing the collars washers and nuts 1 Turn signal light bulb...

Page 84: ...arting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like...

Page 85: ...or replace the spark plugs Have a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slo...

Page 86: ... pressure to escape When the hiss ing sound has stopped press down on the cap 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 cool ant 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...

Page 87: ...ng 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers 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 sprock ets the drive ch...

Page 88: ...ve dirt with warm water a 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 ...

Page 89: ...s t Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product t Avoid using abrasive polishing compounds as they will wear away the paint TIP t Consult a Yamaha dealer for ad vice on what products to use t 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 mois...

Page 90: ... electrodes while turning the engine over EWA10952 e Remove the spark plug caps from the spark plugs and then install 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 th...

Page 91: ... Cylinder arrangement Inline Number of cylinders 2 cylinder Displacement 689 cm Bore stroke 80 0 68 6 mm 3 15 2 70 in Starting system Electric starter Engine oil Recommended brand SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Oil change 2 30 L 2 43 US qt 2 02 Imp qt With oil ter removal 2 60 L 2 75 US qt 2 29 Imp qt Cool...

Page 92: ...pe Tubeless Size 120 70 ZR 17M C 58W Manufacturer model MICHELIN PILOT ROAD 4 Manufacturer model BRIDGESTONE BT023F F Rear tire Type Tubeless Size 180 55 ZR 17M C 73W Manufacturer model MICHELIN PILOT ROAD 4 Manufacturer model BRIDGESTONE BT023R M Loading Maximum load 172 kg 379 lb Total weight of rider passenger cargo and accessories Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acc...

Page 93: ...Specifications 8 3 8 Bulb wattage Headlight H4 60 0 W 55 0 W Brake tail light LED Front turn signal light 10 0 W Rear turn signal light 10 0 W Auxiliary light 5 0 W License plate light 5 0 W ...

Page 94: ...CATION NUMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION EAU26401 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 your motorcy cle with the licensing authority in your area EAU26442 Engine serial num...

Page 95: ...nd de velopment purposes This data will be uploaded only when a special Yamaha diagnostic tool is attached to the vehi cle such as when maintenance checks or service procedures are performed Although the sensors and recorded data will vary by model the main data points are t Vehicle status and engine perfor mance data t Fuel injection and emission relat ed data Yamaha will not disclose this data t...

Page 96: ...ng 5 3 Fuel tank cap 3 16 Fuel tank overflow hose 3 18 Fuses replacing 6 29 H Handlebar switches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 31 Helmet holding cable 3 21 High beam indicator light 3 4 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 26 Immobilizer system 3 1 Immobilizer system indicator light 3 5 Indicator lights and warning lights 3 4 L Licens...

Page 97: ...oubleshooting 6 35 Troubleshooting charts 6 36 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 33 Turn signal switch 3 13 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheels 6 17 ...

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