Yamaha R-3 Owner'S Manual Download Page 69 | Manualshive

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Perio

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ic maintenance an

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a

d

justment

7-22

7

EAU22393

Checkin

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the front an

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rear

b

rake pa

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s

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

EAU22433

Front

b

rake pa

d

s

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear

indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU36721

Rear

b

rake pa

d

s

Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU66670

Checkin

g

the

b

rake flui

d

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

b

rake

1. Brake pad wear indicator groove

1

1

1. Brake pad wear indicator groove

1

1

1. Minimum level mark

1

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Summary of Contents for R-3

Page 1: ...DIC183 B7P F8199 EZ YZF320 A OWNER S MANUAL Read this manual carefully before operating this vehicle ...

Page 2: ...EAU46094 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB7PEZE0 book Page 1 Thursday May 9 2019 9 34 AM ...

Page 3: ...ry 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 this manual contains the most cur re...

Page 4: ...ential 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 easier or clearer WARNING ...

Page 5: ...ndonesia Motor Manufacturing 1st edition September 2019 All rights reserved Any reprinting or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufac turing is expressly prohibited Printed in Indonesia UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 6: ...tion 6 4 Parking 6 4 Periodic maintenance and adjustment 7 1 Tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 5 Checking the spark plugs 7 9 Canister 7 10 Engine oil and oil filter cartridge 7 10 Why Yamalube 7 13 Coolant 7 13 Replacing the air filter element and cleaning the check hose 7 16 Checking the throttle grip free play...

Page 7: ...signal light bulb 7 34 Replacing the license plate light bulb 7 35 Supporting the motorcycle 7 36 Troubleshooting 7 36 Troubleshooting chart 7 38 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 Vehicle data recording 10 2 Index 11 1 UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 8: ...vehicle They contain important 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 1 3 2 UB7PEZE0 book Page 1 Thursday May 9 2019 9 34 AM ...

Page 9: ...Location of important labels 1 2 1 1 3 2 100kPa 1bar kPa psi kPa psi 200 29 250 36 200 29 250 36 2MS F1668 00 UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 10: ...st 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 5 1 for a list of pre operation checks z This motorcycle is designed to carry the operator and a passen ger z The failure of motorists to detect and...

Page 11: ...in tain control of the motorcycle 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 z Never ride under the influence of alcohol or other drugs z This motorcycle is designed for on road use only It is not...

Page 12: ...orcycle 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 senger accessories and car...

Page 13: ... 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 z Never install accessories or carry cargo that would impair the per formance of your motorcycle ...

Page 14: ... are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport z The suspension should be com pressed somewhat by the tie downs if possible so that the mo tor...

Page 15: ...ity of fatalities from motorcycle or scooter accidents are the result of head injuries The use of a safety hel met is the single most critical factor in the prevention or reduction of head in juries Always select an approved motorcy cle helmet Pay attention to the following when choosing a motorcycle helmet z The helmet must meet the safety standard TIS z The helmet size must match the size of the...

Page 16: ...formation 2 7 2 z Full type use only for riding at low to mid range speeds z Full face type use for riding at mid range to high speeds ZAUU0004 ZAUU0005 ZAUU0006 UB7PEZE0 book Page 7 Thursday May 9 2019 9 34 AM ...

Page 17: ...ol kit page 7 2 4 Passenger seat lock page 4 15 5 Storage compartment page 4 17 6 Shock absorber assembly spring preload adjusting ring page 4 18 7 Shift pedal page 4 11 8 Engine oil drain bolt page 7 10 9 Engine oil filter cartridge page 7 10 10 Canister page 7 10 UB7PEZE0 book Page 1 Thursday May 9 2019 9 34 AM ...

Page 18: ...ery page 7 30 3 Fuel tank cap page 4 13 4 Headlight page 7 34 5 Engine oil filler cap page 7 10 6 Engine oil level check window page 7 10 7 Brake pedal page 4 11 8 Rear brake light switch page 7 21 9 Rear brake fluid reservoir page 7 22 UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 19: ... 4 10 2 Left handlebar switches page 4 9 3 Multi function meter unit page 4 3 4 Main switch steering lock page 4 1 5 Front brake fluid reservoir page 7 22 6 Right handlebar switches page 4 9 7 Throttle grip page 7 17 8 Brake lever page 4 11 UB7PEZE0 book Page 3 Thursday May 9 2019 9 34 AM ...

Page 20: ...t ically when the engine is started EAU10662 OFF All electrical systems are off The key can be removed WARNING EWA10062 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 EAU1068B LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steer...

Page 21: ... This warning light comes on when the engine oil pressure is low TIP When the vehicle is turned on the light should come on and remain on until the engine is started Otherwise have a Yamaha dealer check the vehicle NOTICE ECA21211 If the warning light comes on when the engine is running stop the en gine and check the oil level If the oil level is low add sufficient oil of the recommended type If t...

Page 22: ... caution to avoid pos sible wheel lock during emer gency braking z Have a Yamaha dealer check the vehicle as soon as possible TIP The ABS warning light may come on while revving the engine with the vehi cle on its centerstand but this does not indicate a malfunction EAU67433 Shift indicator light This indicator light comes on when it is time to shift to the next higher gear The engine speeds at wh...

Page 23: ... and RE SET buttons for two seconds The hour digits will flash 3 Push the RESET button to set the hours 4 Push the SELECT button The minute digits will flash 5 Push the RESET button to set the minutes 6 Push the SELECT button 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 from F full towards E empty as th...

Page 24: ...ear display This display shows the selected gear The neutral position is indicated by Multi function display This display can show the following items z odometer ODO z tripmeters TRIP 1 and TRIP 2 z fuel reserve tripmeter TRIP F z instant fuel consumption MPG km L L 100 km z average fuel consumption AVE_ _ _ MPG AVE_ _ _ km L AVE_ _ _ L 100 km z oil change tripmeter OIL TRIP Changing and resetting...

Page 25: ...ng the distance traveled from that point After refueling and traveling 5 km 3 mi the fuel reserve trip meter will automatically reset and disappear TIP z The tripmeters will reset and con tinue counting after 9999 9 z The odometer cannot be reset and will lock at 999999 Instantaneous fuel consumption display The instantaneous fuel consumption display can be set to km L or L 100 km or when using mi...

Page 26: ...L will first flash at 1000 km 600 mi then 4000 km 2400 mi later and then every 5000 km 3000 mi to re mind you that the engine oil should be changed After changing the engine oil be sure to reset the oil change tripmeter and the oil change indicator To reset them select the oil change tripmeter and then push the RESET button for one second Then while OIL and the oil change tripmeter are flashing pu...

Page 27: ...tivated in other words it does not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to con firm the selected flashing pattern The shift indicator light changes to the activation point setting mode The tachometer will show the current setting r min for the activation point and deactivation point setting modes To set the shift...

Page 28: ...returns to the standard multi function dis play mode EAU1234M Handlebar switches Left Right EAU12362 Pass switch PASS Press this switch to flash the headlight TIP When the dimmer switch is set to the passing switch has no ef fect EAU85410 Dimmer switch Set this switch to for the high beam and to for the low beam TIP When the switch is set to low beam both headlights for low beam come on When the s...

Page 29: ...n case of an emergency such as to warn other drivers when your vehicle is stopped where it might be a traffic haz ard Set this switch to to turn on the hazard lights To turn off the hazard lights set the switch to OFF NOTICE ECA10062 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12823 Clutch lever To disengage the d...

Page 30: ... gear move the shift pedal down See page 6 3 EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever toward the throttle grip EAU12944 Brake pedal The brake pedal is located on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 1 Brake lever 1 1 Brake pedal 1 UB7PEZE0 book Page 11...

Page 31: ...which will revert the system to conven tional braking if a malfunction occurs TIP z 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 pedal is even slightly appl...

Page 32: ...ire 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 while in the vi cinity of spa...

Page 33: ...er If gaso line spills on your clothing change your clothes EAUU0045 NOTICE ECA11401 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 Gasohol There are two types of gasohol gaso hol containing ethanol and that con taining methanol Gasohol containing ethanol can be used if the...

Page 34: ... burns z Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn z Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system z Make sure that the exhaust sys tem has cooled down before doing any maintenance work z Do not allow the engine to idle more than a few minutes Long idling can cause a build up of he...

Page 35: ...by remov ing the bolts Lift the rear of the rider seat and pull it backward To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then place the seat in the original position 2 Install the rider seat bolts 3 Install the center cover by install ing the screws 4 Install the passenger seat TIP Make sure that the seats are properly secured b...

Page 36: ...elease a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU62550 Storage compartment The storage compartment is located under the passenger seat See page 4 15 When storing documents or other items in the storage compartment be sure to wrap them in a plastic bag so that they will not get wet When wash ing the vehicle be caref...

Page 37: ...he maximum or minimum settings Adjust the spring preload as follows TIP For ABS models remove the drive chain guard by removing the bolts and collars Turn the adjusting ring in direction a to increase the spring preload Turn the adjusting ring in direction b to decrease the spring preload z Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber z Use t...

Page 38: ...n 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 otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off s...

Page 39: ...gine 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 this system via the following procedure TIP z This check is most reliable if per formed with a warmed up engine z See pages 4 1 for switch opera tion information UB7PEZE0 book Page 20 Thursday May 9 2019 9 3...

Page 40: ... 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 Yamaha dealer The sidest...

Page 41: ...points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or damage and check hose connections 4 13 4 15 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 10 Coolant Check coolant level in reservoir If necess...

Page 42: ...ttle grip free play and lubricate ca ble and grip housing 7 17 7 27 Control cables Make sure that operation is smooth Lubricate if necessary 7 26 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 24 7 26 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 18 7 20 Brake and shift pedals Make ...

Page 43: ... tightened Tighten if necessary Instruments lights signals and switches Check 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 19 ITEM CHECKS PAGE UB7PEZE0 book Page 3 Thursday May 9 2019 9 34 AM ...

Page 44: ... 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 operation above 7000 r min NOTICE After 1000 km 600 mi of operation the engine oil must be changed and the oil filter...

Page 45: ...ibed above have a Yamaha dealer check the vehicle 3 Shift the transmission into the neutral position 4 Start the engine by pushing the start switch 5 Release the start switch when the engine starts or after 5 seconds Wait 10 seconds before pressing the switch again to allow battery voltage to restore NOTICE ECA11043 For maximum engine life never ac celerate hard when the engine is cold EAUM3632 TI...

Page 46: ...edal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10261 z Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission z Always use...

Page 47: ...ing it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU17214 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10312 z 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 z Do not park on a slope or on soft g...

Page 48: ...erforming maintenance unless otherwise specified z A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires z Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more in formation about carbon monox ide WARNING EWA15461 Brake discs calipers...

Page 49: ... 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 2 O ring 1 2 UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 50: ...nance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition Replace if necessary 3 Spark plugs Check condition Clean and regap Replace 4 Valves Ch...

Page 51: ...alve and hose for damage Replace any damaged parts if necessary NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km or 5 months 10000 km or 10 months 15000 km or 15 months 20000 km or 20 months UB7PEZE0 book Page 4 Thursday May 9 2019 9 34 AM ...

Page 52: ...element Replace Every 15000 km 9000 mi 3 Air filter check hose Clean 4 Battery Check voltage Charge if necessary 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 8 Brake hoses Check ...

Page 53: ...m 500 mi and after washing the motorcycle riding in the rain or riding in wet areas 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Brake lever pivot shaft Lubricate with silicone grease 18 Brake pedal pivot shaft Lubricate with...

Page 54: ... operation and shock ab sorber for oil leakage 25 Engine oil Change Check oil level and vehicle for oil leakage 26 Engine oil filter car tridge Replace 27 Cooling system Check coolant level and vehicle for coolant leakage Change with Yamaha genuine coolant Every 3 years 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate NO ITEM CHECK OR MAINTENANCE JOB ODOMETER R...

Page 55: ...pers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 30 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 31 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 1 month 5000 km ...

Page 56: ...gine could be operating improperly Do not at tempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs 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 surfa...

Page 57: ...d it in an upright posi tion 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 engine oil level check window located at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If t...

Page 58: ...ter wrench TIP An oil filter wrench is available at a Yamaha 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 with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt 2 Gasket 2 1 1 Oil filter wrench 2 Oil filt...

Page 59: ...s of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher z Make sure that no foreign 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 immediately turn the engine off and check for the cause TIP After the engine is started the engine oil pressure warning lig...

Page 60: ... addi tives to make sure the final oil clears our performance standards Thus Yamalube mineral semisynthetic and synthetic oils have their own distinct characters and value Yamaha s expe rience gained over many years of re search and development into oil since the 1960 s helps make Yamalube the best choice for your Yamaha engine EAU20071 Coolant The coolant level should be checked before each ride ...

Page 61: ...minimum level mark remove the upper panel left side cowling and coolant reservoir cover to access the coolant reservoir 1 Left side panel 2 Bolt 1 2 1 Maximum level mark 2 Minimum level mark 3 Coolant reservoir 3 1 2 1 Upper panel 2 Quick fastener 3 Bolt 4 Left side cowling 5 Nut and washer 6 Screw 1 Bolt 2 Coolant reservoir cover 3 3 2 1 4 6 5 3 2 1 UB7PEZE0 book Page 14 Thursday May 9 2019 9 34 ...

Page 62: ...oolant 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 6 Install the coolant reservoir cover 7 Install the left side cowling and then install the upper panel TIP Fit the projections on the cowling into the holes as shown 8 Install the left side panel EAU33032 Changing the coolant The coolant m...

Page 63: ...leaned if neces sary To replace the air filter element 1 Remove the rider seat See page 4 15 2 Remove the left side panel by re moving the bolts 3 Remove the fuel tank cover by re moving the bolts and quick fas teners 4 Remove the air filter case cover by removing the screws 5 Pull the air filter element out 6 Insert a new air filter element into the air filter case NOTICE Make sure that the air f...

Page 64: ... side panel by install ing the bolts 10 Install the rider seat To clean the air filter check hose 1 Check the hose on the front of the air filter case for accumulated dirt or water 2 If dirt or water is visible remove the hose clean it and then install it 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 65: ...e 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 z The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature z The tire air pr...

Page 66: ...eristics 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 Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use WARNING EWA10462 ...

Page 67: ...ically check the clutch lever free play and if necessary adjust it as fol lows To increase the clutch lever free play turn the clutch lever free play adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b TIP If the specified clutch lever free play cannot be obtained as described above proceed as follows 1 Fully turn the adju...

Page 68: ...e a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of control and an acci dent EAU36505 Brake light switches The brake light should come on just before braking takes effect The brake light is activated by switches connect ed to the brake lever and brake pedal Since the brake light switches are...

Page 69: ...e the brake pads as a set EAU36721 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a ...

Page 70: ...ust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit valves NOTICE ECA17641 Brake fluid may damage painted surfaces 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...

Page 71: ...n the motorcycle 2 Shift the transmission into the neutral position 3 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows NOTICE Im proper drive chain slack will overload the engine as well as other vital parts of the motorcy cle and can lead to chain slip page or breakage If the drive chain slack is more than the chain can damage the frame swingarm ...

Page 72: ...ain pullers are in the same position for proper wheel alignment 3 Tighten the axle nut then the lock nuts to their specified torques 4 Make sure that the drive chain pullers are in the same position the drive chain slack is correct and the drive chain moves smoothly 5 Install the drive chain puller caps 1 Axle nut 2 Locknut 3 Drive chain puller cap 2 3 1 1 Drive chain slack adjusting nut 1 Alignme...

Page 73: ... drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11112 EAU23098 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 ble...

Page 74: ...lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU44276 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 Brake pedal Shift pedal Recommended lubricant Lithium soap based grease UB7PEZE0 book Page 27 Thursday May 9 201...

Page 75: ...nd should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 If the sidestand does not move up and down smoothly 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 Recommended lubricants Brake lever Silicone...

Page 76: ...ck 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 WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10752 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds...

Page 77: ...e wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU50583 Battery The battery is located under the rider seat It is a VRLA valve regulated lead acid battery There is no need to check th...

Page 78: ...ectrical ac cessories NOTICE ECA16522 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 To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure ...

Page 79: ...y coupler and then slide the cover to its orig inal position 5 Place the tray in its original posi tion and then install the quick fas teners 6 Install the passenger seat Fuse box 1 is located behind the center cover See page 4 15 Fuse box 1 1 Quick fastener 2 Tray 2 1 1 Starter relay cover 2 Starter relay coupler 3 Main fuse 4 Spare main fuse 1 2 3 4 1 Fuse box 1 1 Ignition fuse 2 Signaling syste...

Page 80: ...e dam age to the electrical system and possibly a fire EWA15132 3 Turn the main switch on and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 1 Spare fuse 2 ABS solenoid fuse 3 ABS motor fuse 1 1 2 3 Specified fuses Main fuse 30 0 A Headlight fuse 7 5 A Signaling system fu...

Page 81: ...l light lens by removing the screw 2 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pulling it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light lens by installing the screw NOTICE Do not overtighten the screw oth erwise the lens m...

Page 82: ... pulling it out 4 Remove the burnt out bulb by pulling it out 5 Insert a new bulb into the socket 6 Install the socket together with the bulb by pushing it in 7 Install the rear fender lower panel by installing the bolts and screws 8 Install the mudguard by installing the quick fasteners 1 Mudguard 2 Quick fastener 1 2 1 Bolt 2 Screw 3 Rear fender lower panel 1 License plate light bulb 2 License p...

Page 83: ... a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25872 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting cha...

Page 84: ...riodic maintenance and adjustment 7 37 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UB7PEZE0 book Page 37 Thursday May 9 2019 9 34 AM ...

Page 85: ...ve a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug s 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 slowly The battery is good Dry Wet Try sta...

Page 86: ...s 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 coolant level is low Check the cooling system...

Page 87: ...tenance products are sold under the YAMALUBE brand in many markets worldwide z See your Yamaha dealer for addi tional cleaning tips NOTICE ECA26280 Improper cleaning can cause cos metic and mechanical damage Do not use z high pressure washers or steam jet cleaners Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes trans mission seals and electrical de vice...

Page 88: ...hield with a soft towel or sponge dampened with water and a pH neutral detergent If necessary use a high quality windshield cleaner or polish for motorcycles NOTICE Never use any strong chemicals to clean the windshield Additionally some cleaning compounds for plastic may scratch the wind shield so be sure to test all cleaning products before gen eral application ECA26310 4 Rinse off thoroughly wi...

Page 89: ...rakes or tires z If necessary wash the tires with warm water and a mild deter gent z If necessary clean the brake discs and pads with brake cleaner or acetone z Before riding at higher speeds test the vehicle s braking per formance and cornering behav ior EAU83472 Storage Always store the vehicle in a cool dry place If necessary protect it against dust with a porous cover Be sure the engine and th...

Page 90: ...is will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 7 Lubricate all cont...

Page 91: ...MA Engine oil quantity Oil change 1 80 L 1 90 US qt 1 58 Imp qt With oil filter removal 2 10 L 2 22 US qt 1 85 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 0 81 L 0 86 US qt 0 72 Imp qt Fuel Recommended fuel Unleaded gasoline E10 acceptable Octane number RON 90 Fuel tank capacity 14 L 3 7 US gal 3 1 Imp gal Fuel ...

Page 92: ...single disc brake Front suspension Type Telescopic fork Rear suspension Type Swingarm Electrical system System voltage 12 V Battery Model GTZ8V Voltage capacity 12 V 7 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light 10 0 W Rear turn signal light 10 0 W Auxiliary light LED License plate light 5 0 W UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 93: ...ER ENGINE SERIAL NUMBER EAU62971 Vehicle identification number The vehicle identification number is stamped into the frame under the pas senger seat See page 4 15 TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the crankcase 1 Vehicl...

Page 94: ...ached to the vehicle such as when maintenance checks or service proce dures are performed Yamaha will not disclose this data to a third party except in the following cas es In addition Yamaha may provide vehicle data to a contractor in order to outsource services related to the han dling of vehicle data Even in this case Yamaha will require the contractor to properly handle the vehicle data we pro...

Page 95: ...itches 4 9 Hazard lights switch 4 10 Helmet holders 4 17 Helmets 2 6 High beam indicator light 4 2 Horn switch 4 10 I Identification numbers 10 1 Ignition circuit cut off system 4 20 Indicator lights and warning lights 4 2 L Labels location 1 1 License plate light bulb replacing 7 35 Luggage strap holders 4 19 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emi...

Page 96: ...urn signal indicator lights 4 2 Turn signal light bulb replacing 7 34 Turn signal switch 4 9 V Valve clearance 7 18 Vehicle identification number 10 1 Vehicle lights 7 34 W Wheel bearings checking 7 30 Wheels 7 20 Y Yamalube 7 13 UB7PEZE0 book Page 2 Thursday May 9 2019 9 34 AM ...

Page 97: ...UB7PEZE0 book Page 3 Thursday May 9 2019 9 34 AM ...

Page 98: ...PRINTED IN INDONESIA 2019 09 E DIC183 ...

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