Yamaha XJ6SAP Owner'S Manual Download Page 48 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-2

6

EAU52120

Owner’s tool kit

The owner’s tool kit is located inside the
left sidecase. (See page 3-20.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

TIP

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

1. Owner’s tool kit

1

U1PWEAE0.book Page 2 Tuesday, February 7, 2012 4:21 PM

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Summary of Contents for XJ6SAP

Page 1: ...DIC183 XJ6SAP OWNER S MANUAL Read this manual carefully before operating this vehicle 1PW 28199 EA English E ...

Page 2: ...R Hereby declare that the product Type designation 5SL 00 is in compliance with following norm s or documents R TTE Directive 1999 5 EC EN300 330 2 v1 3 1 2006 01 EN300 330 2 v1 5 1 2010 02 EN60950 1 2006 A11 2009 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC 1 2 3 4 Version up the norm of EN60950 to EN60950 1 To change company name version up of the following norm EN300 330 2...

Page 3: ...n 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 rent p...

Page 4: ...tial 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 NO...

Page 5: ...AL 2012 by Yamaha Motor Co Ltd 1st edition January 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1PWEAE0 book Page 2 Tuesday February 7 2012 4 21 PM ...

Page 6: ...2 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 8 Checking the spark plugs 6 10 Engine oil and oil filter cartridge 6 11 Coolant 6 14 Replacing the air filter element 6 18 Adjusting the engine idling speed 6 19 Checking the throttle grip free play 6 20 Valve clearance 6 20 Tires 6 20 Cast w...

Page 7: ...al light bulb 6 38 Replacing the license plate light bulb 6 39 Auxiliary light bulb 6 40 Troubleshooting 6 40 Troubleshooting charts 6 41 Checking the engine guards and rear guards 6 43 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 U1PWEAE0 book Page 2 Tuesday February 7 2012 4 21 PM ...

Page 8: ...ssen gers The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when...

Page 9: ...se injury or an accident 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 Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide ...

Page 10: ... and pres sure of your tires Never attach any large or heavy items to the handlebar 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 ...

Page 11: ...ese ac cessories may also cause instability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories...

Page 12: ...for example to rubber mounted handlebars or turn signals or parts that could break Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs if possible so that the mo torcycle will not bounce excessive ly during transport U1PWEAE0 book Page 5 Tuesday February 7 2012 4 21 PM ...

Page 13: ...le adjusting screw page 6 19 4 Seat lock page 3 18 5 Main fuse page 6 35 6 Owner s tool kit page 6 2 7 Sidecase page 3 20 8 Rear guard page 6 43 9 Shift pedal page 3 14 10 Engine oil filter cartridge page 6 11 11 Engine oil drain bolt page 6 11 12 Engine guard page 6 43 U1PWEAE0 book Page 1 Tuesday February 7 2012 4 21 PM ...

Page 14: ...d reservoir page 6 26 4 Engine oil filler cap page 6 11 5 Radiator cap page 6 14 6 Coolant reservoir page 6 14 7 Coolant drain bolt page 6 15 8 Engine oil dipstick page 6 11 9 Brake pedal page 3 14 10 Shock absorber assembly spring preload adjusting ring page 3 21 U1PWEAE0 book Page 2 Tuesday February 7 2012 4 21 PM ...

Page 15: ...13 2 Left handlebar switches page 3 12 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Front brake fluid reservoir page 6 26 6 Right handlebar switches page 3 12 7 Throttle grip page 6 20 8 Brake lever page 3 14 U1PWEAE0 book Page 3 Tuesday February 7 2012 4 21 PM ...

Page 16: ...DIATELY 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 standard key and keep the co...

Page 17: ...e place and only use it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light 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 stalls EAU10661 OFF All el...

Page 18: ...y in and then turn it to OFF while still pushing it EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an extend...

Page 19: ...s is not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU1142A Coolant temp...

Page 20: ...n gine if it is overheating TIP For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 42 for further instructions U1PWEAE0 book Page 5 Tuesday February 7 2012 4 21 PM ...

Page 21: ... with riding 117 134 C 243 274 F Coolant temperature flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 42 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 ABS ABS U1PWEAE0 book Page 6 Tuesday February 7 2012 4 ...

Page 22: ...rning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check t...

Page 23: ...o turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will swee...

Page 24: ... TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 2 L 0 85 US gal 0 70 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display...

Page 25: ...cuit Coolant temperature display The coolant temperature display indi cates the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the displ...

Page 26: ...ng Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered NOTICE ECA11590 If the...

Page 27: ...EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU42340 The engine trouble warning light and ...

Page 28: ... be used only when the main switch is in the ON position EAU52160 Patrol switch S M P OFF With the key in the ON position use this switch to turn on the patrol lights The following table indicates which ac cessories are enabled when the patrol switch is turned to the P M or S po sition EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lev...

Page 29: ... equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip turn the ad justing dial while holding the lever pushed away from the throttle grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the ...

Page 30: ... the seat and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but these do not indicate a mal function When the ABS is activated the brakes are operated in the usual way A pulsating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner to experience th...

Page 31: ... fuel is a fire hazard EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 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 c...

Page 32: ...as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU51190 Fuel tank breather hose and overflow h...

Page 33: ...are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU53661 Seat To remove the seat 1 Remove...

Page 34: ...e carrier by installing the bolts and nuts and then tighten the nuts to the specified torque EAU47260 Rear view mirrors The rear view mirrors of this vehicle can be folded forward for parking in narrow spaces Fold the mirrors back to their original position before riding WARNING EWA14371 Be sure to fold the rear view mirrors back to their original position before riding 1 Seat lock 2 Unlock 1 2 1 ...

Page 35: ... 406 lb for the ve hicle Do not exceed 130 km h 80 mi h when riding with luggage in the sidecases otherwise han dling could be affected Improp er loading poor tire or overall motorcycle conditions poor road surfaces or adverse weath er conditions may make it nec essary to further reduce the riding speed To open a sidecase 1 Insert the key into the lock and then turn it counterclockwise 2 Turn the ...

Page 36: ... s tool kit to make the adjustment WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or 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 ex plode due...

Page 37: ...ons See the following section for an expla nation of the ignition circuit cut off sys tem WARNING EWA10241 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 system has been desi...

Page 38: ...ission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure U1...

Page 39: ...lutch lever pulled 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 correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be wo...

Page 40: ...nts 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 dam age and check hose connections 3 16 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 Coolant Check coolant level in reservoir If necessar...

Page 41: ...p free play and lubricate cable and grip housing 6 20 6 30 Control cables Make sure that operation is smooth Lubricate if necessary 6 29 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 27 6 29 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 20 6 23 Brake and shift pedals Make sure that...

Page 42: ...ightened 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 3 22 ITEM CHECKS PAGE U1PWEAE0 book Page 3 Tuesday February 7 2012 4 21 PM ...

Page 43: ...h an engine auto stop system The engine stops automatically if left idling for 20 minutes In this case the multi function meter unit indi cates error code 70 but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU43125 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met...

Page 44: ...ac celerate hard when the engine is cold EAU16671 Shifting Shifting gears lets 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 ECA10...

Page 45: ...ully 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 EAU17093 0 1000 km 0 600 mi Avoid prolonged operation above 5800 r min NOTICE ...

Page 46: ... exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire U1PWEAE0 book Page 4 Tuesday February 7 2012 4 21 PM ...

Page 47: ... performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 2 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers d...

Page 48: ...the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit 1 U1PWEAE0 book Page 2 Tuesday February...

Page 49: ... Periodic maintenance chart for the 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 Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Fuel injection Adjust e...

Page 50: ...l and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 6 Wheels Check runout and for damage 7 Tires Check tread depth and for dam age Replace if necessary Che...

Page 51: ...e Every 20000 km 12000 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based grease 16 Shift pedal pivot shaft Lubricate with lithium soap based grease 17 Sidestand center stand ...

Page 52: ...akage Change with ethylene glycol anti freeze coolant Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL ...

Page 53: ... filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1PWEAE0 book Page 7 Tuesday Fe...

Page 54: ... moved and installed EAU46740 Cowling A To remove the cowling Remove the bolts and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU47582 Cowlings B and C To remove a cowling 1 Remove panel B if removing cowl ing B or panel C if removing cowl ing C 1 Cowling A 2 Cowling B 1 2 1 Panel A 2 Cowling C 1 Panel B 2 Panel C 2 1 2 1...

Page 55: ... bolts and the quick fastener 3 Install panel B or C EAU46770 Panel A To remove the panel Remove the bolt and the quick fasten er and then take the panel off To install the panel Place the panel in the original position and then install the bolt and the quick fastener EAU47881 Panels B and C To remove a panel 1 Remove the bolts 1 Cowling B 2 Bolt 3 Quick fastener 1 Turn signal light lead connector...

Page 56: ...ation chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be op...

Page 57: ... checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand 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 unt...

Page 58: ... 6 8 2 Start the engine warm 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 dipstick 2...

Page 59: ...on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial ...

Page 60: ... level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU47560 To check the coolant level 1 Place the vehicle on the center stand TIP The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when che...

Page 61: ...ntent of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Route the coolant reservoir breath er hose through the guide as shown EAU47573 To change the coolant 1 Place the vehicle on the center stand 2 Remove cowlings A and C See page 6 8 3 Place a container under the engine to collect the used coolant 4 Remove the radiator cap retaining bolt rad...

Page 62: ...h the cool ing system with clean tap water 10 Install the coolant drain bolt and its new gasket and then tighten the bolt to the specified torque 11 Install the coolant reservoir and its cover by placing them in the origi nal position and then installing the bolts 12 Pour the specified amount of the recommended coolant into the ra diator and reservoir 1 Coolant reservoir cap 2 Coolant reservoir br...

Page 63: ... then install the cap 18 Route the coolant reservoir breath er hose through the guide as shown 19 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 20 Install the cowlings Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum e...

Page 64: ... sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10481 7 Install the air filter case cover by in stalling the screws 8 Place the fuel tank in its original position Make sure that the fuel hoses are properly connected and rou...

Page 65: ...art The engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make...

Page 66: ...ication chart EAU21503 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10441 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire...

Page 67: ...ility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience to do so 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 air pressure measured on cold tires 0 90...

Page 68: ...tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximate...

Page 69: ...ee play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 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 obt...

Page 70: ... A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have 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 1 Locknut 2 Clutch lever free play adjusting nut 1 2 a b 1 No brake le...

Page 71: ...e 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 disap peared have a Yamaha dealer replace the brake pads as a set EAU46291 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out...

Page 72: ...only the specified brake flu id otherwise the rubber seals may deteriorate causing leak age Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17640 B...

Page 73: ...ke hoses re placed at the intervals listed below or whenever they are damaged or leak ing Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22794 To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neu tral pos...

Page 74: ...rts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack with in the specified limits ECA10571 TIP Using the alignment marks on each side of the swingarm make sure that the notch on the alignment plates is in the same position on both sides for proper wheel alignment 5 Take the motorcycle off the center stand and then put the sidest...

Page 75: ...pe 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 ECA11111 EAU23095 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 ...

Page 76: ...bricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart EAU44273 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 U1PWEAE0 book Page 30 Tuesday February 7 2...

Page 77: ...the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10741 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of co...

Page 78: ...ation chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if th...

Page 79: ...center stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling over EWA10751 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 EAU23291 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in...

Page 80: ...it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16521 To charge a VRLA Valve Regulated Lead Acid battery a special c...

Page 81: ...es are located under the seat See page 3 18 TIP To access the main fuse remove the starter relay cover as shown The siren fuse and the patrol light fuse are located behind the front cowling 1 Starter relay cover 2 Main fuse 3 Spare main fuse 4 Fuse box 2 4 3 1 1 Taillight fuse 2 ABS control unit fuse 3 Police system fuse 4 ABS solenoid fuse 5 ABS motor fuse 6 Spare fuse 7 Headlight fuse 8 Ignition...

Page 82: ...nd 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 Spare fuse 2 Siren fuse 3 Patrol light fuse 1 2 3 Specified fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan fuse 20 0 A Fuel injection system fuse 10 0 ...

Page 83: ...ol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove cowling B See page 6 8 2 Disconnect the headlight coupler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the burnt out bulb 4 Place a new headlight bulb into po sition and then secure...

Page 84: ... new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the seat EAU24204 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 counter clockwise 1 Tail brake light bulb socket 1 1 Tail brake light bulb 2 Tail brake light bulb socket 2 1 1 Turn signal l...

Page 85: ...e plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws 1 Turn signal light bulb 1 1 License plate light unit 2 Screw 2 ...

Page 86: ...vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING...

Page 87: ...r check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns ov...

Page 88: ...hissing 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 OK The coolant level is low Check the...

Page 89: ...hecking the engine guards and rear guards Check the guards for damage and the mounting bolts for looseness If the guards are significantly bent or de formed replace them 1 Engine guard 2 Rear guard 2 1 U1PWEAE0 book Page 43 Tuesday February 7 2012 4 21 PM ...

Page 90: ...utlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always...

Page 91: ...ld detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosi...

Page 92: ... to any rubber and plastic parts 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 EAU26182 Stor...

Page 93: ...he engine over EWA10951 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 the ground Alterna tively tur...

Page 94: ... Imp qt With oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 17 3 L 4 57 US gal 3 81 Imp...

Page 95: ...kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT4 50 Front brake Type Dual disc brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Single disc brake Operation Right foot ...

Page 96: ...ight LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan fuse 20 0 A Fuel injection system fuse 10 0 A ABS control unit fuse 7 ...

Page 97: ...tion 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 EAU26480 Model label The model label is affixed to the frame under the seat See page 3 18 Record the information on this label in the space provid...

Page 98: ...nt fork checking 6 32 Fuel 3 16 Fuel consumption tips for reducing 5 3 Fuel tank breather hose and overflow hose 3 17 Fuel tank cap 3 16 Fuses replacing 6 35 H Handlebar switches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 37 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 23 Immobilizer system 3 1 Immobilizer system indicator li...

Page 99: ... Tool kit 6 2 Troubleshooting 6 40 Troubleshooting charts 6 41 Turn signal indicator light 3 4 Turn signal light bulb replacing 6 38 Turn signal switch 3 12 V Valve clearance 6 20 Vehicle identification number 9 1 W Wheel bearings checking 6 33 Wheels 6 23 U1PWEAE0 book Page 2 Tuesday February 7 2012 4 21 PM ...

Page 100: ...A5 yoko_Blank fm Page 1 Monday July 11 2011 4 13 PM ...

Page 101: ...A5 yoko_Blank fm Page 1 Monday July 11 2011 4 13 PM ...

Page 102: ...PRINTED IN JAPAN 2012 02 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER ...

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