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PERIODIC MAINTENANCE AND ADJUSTMENT

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1. Air filter element

ECA10480

NOTICE

●

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

●

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

5. Install the air filter case cover by

installing the screws.

6. Install the seat.

1

EAUB1480

Replacing the air filter
element and cleaning the
check hose

The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary.

To replace the air filter element

1. Air filter case
2. Screws

1. Remove the seat. (See page 4-

14.)

2. Remove the air filter case cover

by removing the screws.

3. Pull the air filter element out.
4. Insert a new air filter element into

the air filter case as shown.

XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-14

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Summary of Contents for TENERE XT660Z

Page 1: ...11D F8199 21 XT660Z OWNER S MANUAL Read this manual carefully before operating this vehicle 03 ingles australia 26 2 10 10 51 Página 1 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 2 ...

Page 3: ...ury 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 curre...

Page 4: ...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 EAU10132 NOTICE XT660Z 01 03 ING AUS AU...

Page 5: ...ANUAL 2010 by Yamaha Motor España S A 1st edition May 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor España S A is expressly prohibited Printed in Spain 03 ingles australia 26 2 10 10 45 Página 5 ...

Page 6: ... absorber assembly 4 16 Sidestand 4 17 Ignition circuit cut off system 4 17 FOR YOUR SAFETY PRE OPERATION CHECKS 5 1 Pre operation check list 5 2 OPERATION AND IMPORTANT RIDING POINTS 6 1 Starting the engine 6 1 Shifting 6 2 Tips for reducing fuel consumption 6 3 Engine break in 6 3 Parking 6 4 PERIODIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 1 Periodic maintenance chart for the emission...

Page 7: ...cking the wheel bearings 7 29 Battery 7 30 Replacing the fuses 7 31 Replacing a headlight bulb 7 33 Replacing a turn signal light bulb 7 34 Replacing the license plate light bulb 7 35 Replacing an auxiliary light bulb 7 35 Supporting the motorcycle 7 36 Front wheel 7 36 Rear wheel 7 38 Troubleshooting 7 39 Troubleshooting charts 7 40 MOTORCYCLE CARE AND STORAGE 8 1 Care 8 1 Storage 8 3 SPECIFICATI...

Page 8: ... on your 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 XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 8 ...

Page 9: ...1 2 3 4 5 6 7 8 9 10 LOCATION OF IMPORTANT LABELS 1 2 1 2 3 4 XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 9 ...

Page 10: ... is the predominating cause of automo bile motorcycle accidents Many ac cidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are ...

Page 11: ...control levers footrests or wheels and cause injury or an ac cident Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passenger should also observe the above precautions Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide...

Page 12: ...ndlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can create unstable han dling or a slow steering re sponse This vehicle is not designed to pull a trailer or to be attached to a sidecar Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision Genuine Yamaha accessories which are avail able only from a Yamaha ...

Page 13: ...ould 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 unstable in cross winds These accessories may also cause in stability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or her normal riding po...

Page 14: ...e 7 1 3 Air filter element page 7 14 4 Fuse box page 7 31 5 Seat lock page 4 14 6 Shock absorber assembly spring preload adjusting ring page 4 16 7 Shift pedal page 4 10 8 Engine oil drain bolt crankcase page 7 10 9 Engine oil drain bolt oil tank page 7 10 XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 14 ...

Page 15: ...7 30 13 Rear brake fluid reservoir page 7 22 14 Coolant reservoir page 7 13 15 Front brake fluid reservoir page 7 22 16 Coolant drain bolt page 7 12 17 Engine oil filter element page 7 11 18 Brake pedal page 4 11 EAU10420 Right view XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 15 ...

Page 16: ...s page 4 9 3 Multi function meter unit and warning lights page 4 3 4 5 4 Right handlebar switches page 4 9 5 Throttle grip page 7 16 6 Brake lever page 4 11 7 Engine oil filler cap dipstick page 7 9 8 Fuel tank cap page 4 11 9 Main switch and steering lock page 4 2 XT660Z 01 03 ING AUS AUSTRALIA 11 05 2009 9 57 Pagina 16 ...

Page 17: ...T 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 ve hicle however if code re regis tering is required i e if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recom mended to use either standard ...

Page 18: ...d The key cannot be removed TIP The headlights comes on automatical ly when the engine is started and stay 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 EWA10061 WARNING 0 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may re sult in loss of co...

Page 19: ...on for an extended length of time other wise the battery may discharge EAU11004 Indicator and warning lights 1 Immobilizer system indicator light 2 Neutral indicator light N 3 Turn signal indicator light y 4 High beam indicator light 1 5 Engine trouble warning light U 6 Coolant temperature warning light u EAUB1510 Turn signal indicator light y This indicator light flashes when the turn signal swit...

Page 20: ...witch on or off according to the coolant temperature in the ra diator If the engine overheats see page 7 41 for further instructions EAU11534 Engine trouble warning light U This warning light comes on or flashes if a problem is detected in the electri cal circuit monitoring the engine If this occurs have a Yamaha dealer check the self diagnosis system See page 4 8 for an explanation of the self di...

Page 21: ...ter 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 since the bottom segment of the fuel meter started flashing a clock a fuel meter a self diagnosis device TIP Be sure to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the spe...

Page 22: ...rder TRIP 1 6TRIP 2 6 TRIP 1 When the fuel amount in the fuel tank decreases to 6 7 L 1 77 US gal 1 47 Imp gal the bottom segment of the fuel meter will start flashing and the tripmeter display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case pushing the SELECT but ton switches the display between the various ...

Page 23: ... 1 Fuel meter With the key in the ON position the fuel meter indicates the amount of fuel in the fuel tank When the key is turned to ON all of the display segments of the fuel meter will appear one after the other and then disappear in order to test the electrical circuit The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When only one segment is left near...

Page 24: ...five times and then quickly flashes two times repeatedly this error could be caused by transponder interference If this occurs try the following 1 Use the code re registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobiliz er key on the same key ring Immobi lizer system keys may cause signal in terference w...

Page 25: ...nal a left hand turn push this switch to Ÿ When re leased the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch o Press this switch to sound the horn EAU12660 Engine stop switch I Set this switch to I before starting the engine Set this switch to to stop the engine in case of an emergency su...

Page 26: ...12820 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage the clutch re lease the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 17 1 EA...

Page 27: ...ng dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the ad justing dial is aligned with the mark on the brake lever EAU12941 Brake pedal 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 EAU13074 Fuel tank cap 1 Lock cover 2 Open To open the fuel tank cap Open the fu...

Page 28: ... Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fu el reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engin...

Page 29: ...nocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance costs Recommended fuel PREMIUM UNLEADED GASOLINE ONLY Fuel tank capacity 23 0 L 6 07 US gal 5 05 Imp gal Fuel reserve amount when the fuel level warning light comes on 6 7 L 1 77 US gal 1 47 Imp gal EAU13433 Catalytic converter This model is equipped with a catalyt ...

Page 30: ...sure that the seat is properly se cured before riding EAU32980 Seat To remove the seat 1 Seat lock 2 Unlock 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the rear of the seat up and then pull the seat off ECA10701 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalyt ic conve...

Page 31: ...follows To increase the spring preload and thereby harden the suspension turn the adjusting bolts on each fork leg in direction a To decrease the spring preload and thereby soften the sus pension turn the adjusting bolts on each fork leg in direction b Maximum hard 0 complete turns in direction b Standard 22 complete turns in direction b Minimum soft 27 complete turns in direction b With the adjus...

Page 32: ... attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly...

Page 33: ...of the ignition circuit cut off system which cuts the ignition in certain situa tions See further down for an expla nation of the ignition circuit cut off sys tem 1 1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4 17 EAU15314 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions It pre...

Page 34: ...on into gear 9 Move the sidestand down Does the engine stall The neutral 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 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 Y...

Page 35: ... WARNING 0 Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer 5 1 FOR YOUR SAFETY PRE OPERATION CHECKS 10 9 8 7 6 5 4 3 2 1 XT660Z 05 07 ING AUS MY03 04 06 ING 11 05 ...

Page 36: ...evel Check cooling system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if ...

Page 37: ... operation is smooth Lubricate if necessary Check chain slack Adjust if necessary Check chain condition Lubricate if necessary Check for damage Check tire condition and tread depth Check air pressure Correct if necessary Make sure that operation is smooth Lubricate pedal pivoting points if necessary Make sure that operation is smooth Lubricate lever pivoting points if necessary Make sure that oper...

Page 38: ...hts signals and switches Sidestand switch CHECKS Check operation Correct if necessary Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle PAGE 4 3 4 9 4 17 XT660Z 05 07 ING AUS MY03 04 06 ING 11 05 2009 10 09 Pagina 4 ...

Page 39: ...the key to OFF and then to ON to clear the error code Failing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAUB1570 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 position The transmission is in gear with the clutc...

Page 40: ...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 6 2 1 2 3 4 5 6 7 8 9 10 ECAB0070 NOTICE The following warning lights and in dicator lights should come on for a few seconds then go off Neutral indicator light Turn signal indicator light High beam indicator light Engine tro...

Page 41: ...during acceleration G Do not rev the engine while shift ing down and avoid high engine speeds with no load on the en gine G Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU16841 Engine break in There is never a more important peri od in the life of your engine than the period between 0 and 1600 km 100...

Page 42: ...uring the engine break in period immediately have a Yamaha dealer check the vehicle EAU17213 Parking When parking stop the engine and then remove the key from the main switch EWA10311 WARNING 0 G 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 G Do not park on a slope or on soft ground otherwise the v...

Page 43: ...liar with vehicle service have a Yamaha dealer per form service EAU17391 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located under the seat See page 4 14 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 wr...

Page 44: ...hart for the emission control system 7 2 1 2 3 4 5 6 7 8 9 10 NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km 10000 km 20000 km 30000 km 40000 km 600 mi 6000 mi 12000 mi 18000 mi 24000 mi ANNUAL CHECK 1 2 3 4 5 6 Check fuel hoses for cracks or damage Check condition Clean and regap Replace Check valve clearance Adjust Adjust engine idling speed Check the screw clamp s for looseness Check...

Page 45: ...l and vehicle for fluid leakage Replace brake pads Check for cracks or damage Replace Check runout spoke tightness and for damage Tighten spokes if necessary Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Check bearing for looseness or damage Air filter element Clutch Front brake Rear brake Brake hoses Wheels Tires Wheel bearings EAU1770C General main...

Page 46: ...ed grease Make sure that all nuts bolts and screws are properly tightened Check operation Lubricate Check operation Check operation and for oil leakage Check operation and shock absorber for oil leakage Check operation Lubricate with lithium soap based grease Change Check oil level and vehicle for oil leakage Swingarm Drive chain Steering bearings Chassis fasteners Sidestand Sidestand switch Front...

Page 47: ...ECK OR MAINTENANCE JOB ODOMETER READING 1000 km 10000 km 20000 km 30000 km 40000 km 600 mi 6000 mi 12000 mi 18000 mi 24000 mi ANNUAL CHECK Replace Check coolant level and vehicle for coolant leakage Change Check operation Lubricate Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Check operation Adjust headlight beam Engin...

Page 48: ... panel To remove one of the panels Remove the bolts and then pull the panel off at the areas shown Panel C and D 1 Panel mounting bolt C Right panel D Left panel To remove one of the panels Remove the bolts and then pull the panel off at the areas shown To install the panel Place the panel in the original position and then install the bolts 7 6 1 2 3 4 5 6 7 8 9 10 1 Panel 2 Turn signal light coup...

Page 49: ...el off at the areas shown To install the panel 1 Place the panel in the original posi tion 2 Install the quick fastener and the bolts 1 1 2 E F Panel G 1 Panel mounting bolt G Panel To remove the panel Remove the bolts and then pull the panel off at the areas shown 1 Panel 2 Pin To install the panel Place the panel in the original position and then install the bolts 2 2 1 XT660Z 05 07 ING AUS MY03...

Page 50: ...mm 0 028 0 032 in To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 1 Spark plug gap 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque EAU19603 Ch...

Page 51: ...m it up for 10 15 minutes and then turn it off 3 Remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level 1 Engine oil filler cap 2 Maximum level mark 3 Minimum level mark TIP The engine oil tank is located in side of the frame The engine oil should be between the minimum and maximum level marks...

Page 52: ... drain the oil from the oil tank 1 Engine oil crankcase drain bolt 1 Engine oil tank drain bolt 6 Remove the oil filter element drain bolt to drain the oil from the oil filter element 1 ECA10010 NOTICE Do not operate the vehicle until you know that the engine oil level is suf ficient EWA10360 WARNING 0 Never remove the engine oil tank cap after high speed operation otherwise hot engine oil could s...

Page 53: ...olt 11 Tighten the oil filter element cover bolts and the oil filter element drain bolt to their specified torques 1 Engine oil filter element 2 O rings 12 Install the engine oil drain bolts and then tighten them to their specified torques TIP Skip steps 7 9 if the oil filter element is not being replaced 7 Remove the oil filter element cov er by removing the bolts 8 Remove and replace the oil fil...

Page 54: ...rn the en gine off and check for the cause 15 Turn the engine off and then check the oil level and correct it if necessary 16 Install the engine guard by in stalling the screws EAU20070 Coolant The coolant level should be checked before each ride In addition the coolant must be changed at the inter vals specified in the periodic mainte nance and lubrication chart EAU20253 To check the coolant leve...

Page 55: ... use hard water or salt water since it is harmful to the engine If wa ter has been used instead of coolant replace it with coolant as soon as possible otherwise 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 an tifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant wi...

Page 56: ...nd cleaning the check hose The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas In addition the air filter check hose must be fre quently checked and cleaned if neces sary To replace the air filter element 1 Air filter case 2 Screws 1 ...

Page 57: ...he engine idling speed 1 Idle adjusting screw a Increasing the engine idling speed b Decreasing the engine idling speed The engine idling speed must be checked as follows and if necessary adjusted by a Yamaha dealer at the in tervals specified in the periodic main tenance and lubrication chart Start the engine and warm it up for several minutes at 1000 2000 r min while occasionally revving it to 4...

Page 58: ... The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger cargo and accessories ap proved for this model EAU21382 Checking the throttle cable free play 1 Throttle cable free play The throttle cable free play should measure 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 hav...

Page 59: ...si 2 3 kgf cm2 Rear 250 kPa 36 psi 2 5 kgf cm2 Off road riding Front 200 kPa 29 psi 2 0 kgf cm2 Rear 200 kPa 29 psi 2 0 kgf cm2 High speed riding Front 210 kPa 30 psi 2 1 kgf cm2 Rear 230 kPa 33 psi 2 3 kgf cm2 Maximum load 190 kg 419 lb Total weight of rider passenger cargo and accessories EWA10461 WARNING 0 The front and rear tires should be of the same make and design other wise the handling ch...

Page 60: ...HELIN SIRAC A Tire inspection 1 Tire sidewall 2 Tire tread depth The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yama ha dealer replace the tire immediately TIP The tire tread depth limits may differ from country to country Always com ply with the local regulations ...

Page 61: ...is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed 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 can result in poor performance adverse handling characteristics and a shortened tire life Ride at moderate speeds after changing a tire since...

Page 62: ...6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the adjusting nut in direction b 7 Tighten the locknut at the crankcase 8 Tighten the locknut at the clutch lever and then slide the rubber cover to its original position 1 b a 2 EAU22043 Adjusting the clutch lever free play 1 Locknut 2 Adjusting bolt 3 Clutch lever free play...

Page 63: ... the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost dis appeared have a Yamaha dealer re place the brake pads as a set EAU22500 Rear brake pads 1 Rear brake pad lining thickness Check each rear brake pad for dam age and measure the lining thickness If ...

Page 64: ...ls may deteriorate caus ing leakage and poor braking performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate pai...

Page 65: ...hould be checked before each ride and adjusted if necessary EAU22783 To check the drive chain slack 1 Drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the dri ve chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neutral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the dr...

Page 66: ...4 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting bolt on each side of the swingarm in di rection a To loosen the drive chain turn the adjusting bolt on each side of the swingarm in di rection b and then push the rear wheel forward NOTICE Improp er drive chain slack will over load ...

Page 67: ...te solvents 2 Wipe the 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 EAU23101 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride a...

Page 68: ...c maintenance chart EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease PERIODIC MAINTENANCE AND ADJUSTMENT 7 26 7 03 ingles australia 3 5 ...

Page 69: ...metal contact surfaces should be lubricated if necessary EWA10730 WARNING 0 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 lubricant Lithium soap based grease EAU23250 Lubricating the rear suspension The pivoting points of the ...

Page 70: ...on WARNING To avoid in jury securely support the vehi cle so there is no danger of it falling over 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 smoothly ECA10590 NOTICE If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAUM1650 Lubricating the swingarm p...

Page 71: ...G To avoid injury securely support the vehi cle so there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals spec ified in the periodic maintenance a...

Page 72: ...harging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN EAUB1432 Battery This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the elec trolyte or to add distilled water Howev er the battery lead connections need to be checked and if necessary tight ened ECA10620 NOTICE Never attempt to remove the bat tery cell seals as thi...

Page 73: ...n place it in a cool dry place NO TICE When removing the bat tery be sure the key is turned to OFF then disconnect the negative lead before discon necting the positive lead 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 4 After installation make sure that the battery leads are ...

Page 74: ...se 4 Ignition fuse 5 Electronic fuel injection fuse 6 Radiator fan fuse 7 Backup fuse 8 Reserve fuses The main fuse and fuse box are locat ed under the seat See page 7 31 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 7 8 6 5 4 3 2 1 Specified fuses Main fus...

Page 75: ...ot touch the bulb until it has cooled down 3 Place a new headlight bulb into position and then secure it with the bulb holder 1 Do not touch this area 1 Headlight bulb holder 2 Headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Remove the headlight bulb cover and then disconnect the headlight coupler 2 Unhook the headlight bulb h...

Page 76: ...ns Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage higher than specified 4 Connect the coupler and then in stall the headlight bulb cover 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU24204 Replacing a turn signal light bulb 1 Screw 2 Turn signal light lens 3 Turn signal light bulb 1 Remove the turn signal light le...

Page 77: ...g it out 4 Insert a new bulb into the socket 5 Install the auxiliary light socket together with the bulb by push ing it in 6 Install the panel EAUM2202 Replacing the license plate light bulb 1 Bulb socket 2 License plate light bulb 1 Remove the socket together 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 toge...

Page 78: ...inch bolt B Front wheel axle pinch bolt A 2 B 1 EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precau tions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motorcy cle is in a stable and level position be fore starting any maintenance A strong wooden box can be plac...

Page 79: ...ore in stalling the brake calipers onto the brake discs 4 Lower the front wheel so that it is on the ground 5 Tighten the wheel axle and the brake caliper bolts to the specified torques ECAB0060 NOTICE Be sure the right brake disc is posi tioned exactly in the middle of the caliper pads to prevent any brake drag Tap the side of the right fork leg to position the disc correctly Tightening torques W...

Page 80: ...liper bracket by inserting the wheel axle from the right hand side EAU25080 Rear wheel EAU25312 To remove the rear wheel EWA10821 WARNING 0 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Wheel axle nut 2 Drive chain slack adjusting bolt 3 Locknut 4 Drive chain 3 4 1 1 Wheel axle 2 Drive chain slack adjusting bolt 3 Locknut 4 Brake caliper 1 Loosen the axle ...

Page 81: ... problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle...

Page 82: ...el There is no compression Dry The engine turns over slowly Check the compression Check the ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug The battery is good Have a Yamaha dealer check the vehicle Check the battery lead connections and charge the battery if necessary Operate the electric starter The engine does not start Check the battery The engine do...

Page 83: ...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 coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is low Check the cooling system for...

Page 84: ...aners especially on spoked wheels If such prod ucts are used on hard to re move dirt do not leave the cleaner on the affected area any longer than instructed Al so thoroughly rinse the area off with water immediately dry it and then apply a corrosion protection spray Improper cleaning can damage plastic parts such as cowlings panels windshields headlight lenses meter lenses etc and the mufflers Us...

Page 85: ...wing steps after each ride in the rain near the sea or on salt sprayed roads TIP Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold water and a mild detergent after the engine has cooled down NO TICE Do not use warm water since it increases the corrosive action of the salt 2 Apply a corrosion protection spray on all metal including chrome and nickel pl...

Page 86: ...s but treat them 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 EAUM1901 Storage Short term Always store you...

Page 87: ...plug and then install the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that...

Page 88: ... gal Fuel injection Manufacturer DENSO Model 297500 0390 Spark plug Manufacturer model NGK CR7E Gap 0 7 0 8 mm 0 028 0 032 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 75 36 2 083 Secondary reduction system Chain drive Secondary reduction ratio 45 15 3 00 Transmission type Constant mesh 5 speed Dimensions Overall length 2246 mm 88 ...

Page 89: ...measured on cold tires Load Up to 90 kg 0 198 lb Front 210 kPa 30 psi 2 1 kgf cm2 Rear 230 kPa 33 psi 2 3 kgf cm2 Load 90 190 kg 198 419 lb Front 230 kPa 33 psi 2 3 kgf cm2 Rear 250 kPa 36 psi 2 5 kgf cm2 Off road riding Front 200 kPa 29 psi 2 0 kgf cm2 Rear 200 kPa 29 psi 2 0 kgf cm2 High speed riding Front 210 kPa 30 psi 2 1 kgf cm2 Rear 230 kPa 33 psi 2 3 kgf cm2 Front wheel Type Spoke wheel Ri...

Page 90: ...ry light 12 V 5 W x 2 Tail brake light LED Front turn signal light 12 V 10 W x 2 Rear turn signal light 12 V 10 W x 2 Meter lighting LED backlight Neutral indicator light LED Turn signal indicator light LED High beam indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling sy...

Page 91: ...dentification number 2 Code re registering key red bow 3 Standard keys black bow The key identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when or dering a new key EAU26400 Vehicle identification number 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the...

Page 92: ...NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoper ative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of the vehicle...

Page 93: ...ating the throttle grip and cable 7 26 Checking the brake pedal 7 27 Checking the sidestand switch 4 18 Clock mode 4 7 Clutch lever 4 10 Clutch lever free play adjusting 7 20 Consumer information 10 1 Controls and instruments 3 3 Function 4 1 Coolant 7 12 Coolant temperature warning light 4 4 D Description 3 1 Controls and instrument 3 3 Left view 3 1 Right view 3 2 Dimmer switch 4 9 Drive chain c...

Page 94: ... 27 Lubricating the cables 7 25 Lubricating the drive chain 7 25 Lubricating the sidestand 7 27 Lubricating the throttle grip and cable 7 26 Lubricating the swingarm pivots 7 28 M Main switch steering lock 4 2 Model label 10 2 Motorcycle noise regulation for Australia 10 2 Multi function display 4 5 Clock mode 4 7 Self diagnosis devices 4 7 Tachometer 4 6 Tripmeter and tachometer modes 4 6 N Neutr...

Page 95: ...icating 7 26 Tips for reducing fuel consumption 6 3 Tires 7 16 Air pressure 7 16 Tire information 7 18 Tire inspection 7 18 Tool kit 7 1 Tripmeter and tachometer modes 4 6 Troubleshooting 7 39 Troubleshooting charts 7 40 Engine overheating 7 41 Turn signal indicator light 4 3 Turn signal light bulb replacing 7 34 Turn signal switch 4 9 V Valve clearance 7 16 Vehicle identification number 10 1 W Wa...

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Page 100: ...YAMAHA MOTOR ESPAÑA S A PRINTED IN SPAIN 03 ingles australia 26 2 10 10 45 Página 95 ...

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