Yamaha XSR MTM690 Owner'S Manual Download Page 98

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10-2

Tires ......................................................6-16
Tool kit ....................................................6-2
Troubleshooting ....................................6-37
Troubleshooting charts.........................6-39
Turn signal indicator lights......................3-4
Turn signal light bulb, replacing............6-36
Turn signal switch .................................3-13

Valve clearance.....................................6-16
Vehicle identification number .................9-1

Wheel bearings, checking.....................6-29
Wheels ..................................................6-18

UB34E0E0.book Page 2 Friday, July 10, 2015 10:31 AM

Summary of Contents for XSR MTM690

Page 1: ...PANTONE285C MTM690 MTM690 U OWNER S MANUAL B34 F8199 E0 Read this manual carefully before operating this vehicle English E ...

Page 2: ... 300 330 2 V1 5 1 2010 Technical Construction File held by YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka 437 0292 Japan R TTE Directive Article 3 1 a Safety R TTE Directive Article 3 1 b EMC R TTE Directive Article 3 2 Spectrum DECLARATION of CONFORMITY For YAMAHA MOTOR ELECTRONICS CO LTD 1450 6 Mori Mori machi Shuchi gun Shizuoka ken 437 0292 Japan Standard used for c...

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

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: ... OWNER S MANUAL 2015 by MBK INDUSTRIE 1st edition July 2015 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France UB34E0E0 book Page 2 Friday July 10 2015 10 31 AM ...

Page 6: ...l system 6 3 General maintenance and lubrication chart 6 4 Checking the spark plugs 6 8 Canister 6 9 Engine oil and oil filter cartridge 6 9 Coolant 6 12 Replacing the air filter element and cleaning the check hose 6 15 Checking the throttle grip free play 6 15 Valve clearance 6 16 Tires 6 16 Cast wheels 6 18 Adjusting the clutch lever free play 6 19 Checking the brake lever free play 6 19 Brake l...

Page 7: ...plate light 6 36 Supporting the motorcycle 6 37 Troubleshooting 6 37 Troubleshooting charts 6 39 Motorcycle care and storage 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 Specifications 8 1 Consumer information 9 1 Identification numbers 9 1 Diagnostic connector 9 2 Index 10 1 UB34E0E0 book Page 2 Friday July 10 2015 10 31 AM ...

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

Page 9: ...o main 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 Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not...

Page 10: ...rcycle 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 carg...

Page 11: ... 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 Never install accessories or carry cargo that would impair the per formance of your motorcycle Ca...

Page 12: ...instruc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure th...

Page 13: ... page 3 19 3 Owner s tool kit page 6 2 4 Shift pedal page 3 14 5 Engine oil filler cap page 6 9 6 Engine oil drain bolt page 6 9 7 Engine oil level check window page 6 9 8 Engine oil filter cartridge page 6 9 9 Coolant reservoir page 6 12 UB34E0E0 book Page 1 Friday July 10 2015 10 31 AM ...

Page 14: ...tery page 6 29 4 Shock absorber assembly spring preload adjusting ring page 3 21 5 Fuel tank cap page 3 16 6 Headlight page 6 33 7 Coolant drain bolt page 6 13 8 Brake pedal page 3 14 9 Rear brake light switch page 6 20 10 Rear brake fluid reservoir page 6 21 UB34E0E0 book Page 2 Friday July 10 2015 10 31 AM ...

Page 15: ...lutch lever page 3 13 2 Left handlebar switches page 3 12 3 Multi function meter unit page 3 6 4 Front brake fluid reservoir page 6 21 5 Right handlebar switches page 3 12 6 Throttle grip page 6 15 7 Brake lever page 3 14 UB34E0E0 book Page 3 Friday July 10 2015 10 31 AM ...

Page 16: ...EDIATELY 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 c...

Page 17: ...e and only use it for code re registering EAU38531 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 EAU10662 OFF All electric...

Page 18: ...rs back to the right slight ly To unlock the steering 1 Insert the key 2 With the key in the LOCK posi tion push the key in and turn it to OFF EAU59680 Parking The hazard lights and turn signal lights can be turned on but all other electri cal systems are off The key can be re moved The steering must be locked before the key can be turned to NOTICE ECA20760 Using the hazard or turn signal lights f...

Page 19: ...engine is running stop the en gine immediately and check oil level If the oil level is below the minimum level add sufficient oil of the recom mended type to raise it up to the cor rect level If the oil pressure warning light remains on even if the oil level is correct immediately turn the en gine off and have a Yamaha dealer check the vehicle TIP If the warning light does not go off after startin...

Page 20: ... 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 the electrical circuit EAU69890 ABS warning light In normal operation the ABS warning light comes on when the key is turned to ON and goes off after traveling at a speed of 10 km h 6 mi h or higher If the ABS warning light does not come on when the key is turned ...

Page 21: ... dicator light will flash in a pattern to indicate an error code TIP If the immobilizer system indicator light flashes in the pattern slowly 5 times and then quickly 2 times this could be caused by transponder interference If this occurs try the following 1 Make sure there are no other im mobilizer keys close to the main switch Other immobilizer system keys may cause signal interfer ence and preve...

Page 22: ...ode or a tripmeter mode and then press the bottom set button for three seconds Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range NOTICE ECA10032 Do not operate the engine in the ta chometer red zone Red zone 10000 r min and above Fuel meter The fuel meter indicates the amou...

Page 23: ...le speed Transmission gear display This display shows the selected gear The neutral position is indicated by and by the neutral indicator light Multi function display The multi function display is equipped with the following an odometer two tripmeters a fuel reserve tripmeter an instantaneous fuel consump tion display an average fuel consumption dis play a coolant temperature display an air temper...

Page 24: ...L L 100 km or MPG AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG _ _ C Air_ _ C Clock _ _ _ _ ODO TIP Push the top set button to switch the display in the reverse order The fuel reserve tripmeter and er ror code displays come on auto matically while the brightness control mode is accessed sepa rately If the lower segment and frame of the fuel meter start flashing the display automatically changes...

Page 25: ...uel consumption since it was last reset The average fuel consumption display can be set to either AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG for the UK AVE_ _ _ km L The average dis tance that can be traveled on 1 0 L of fuel AVE_ _ _ L 100 km The average amount of fuel necessary to travel 100 km AVE_ _ _ MPG The average distance that can be traveled on 1 0 Imp gal of fuel To switch the avera...

Page 26: ...hen stopped at traffic signals railroad crossings etc Clock The clock displays time in 12 hour for mat Even when the key is not in the ON position the clock can be viewed for 10 seconds by pushing the bottom set button To set the clock 1 Turn the key to ON 2 Push the bottom set button and top set button together for two seconds and the hour digits will start flashing 3 Push the top set button to s...

Page 27: ...ton un til the display switches to the brightness control mode 4 Push the top set button to set the brightness level 5 Push the bottom set button to confirm the selected brightness level and exit the brightness con trol mode TIP There are 6 brightness level settings EAU1234H Handlebar switches Left Right 1 Brightness level display ZAUM1341 1 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Hor...

Page 28: ...ergency such as when the vehicle overturns or when the throttle cable is stuck EAU12735 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard NOTICE ECA10062 Do not use t...

Page 29: ... 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 EAU12944 Brake pedal The brake pedal is located on the right side of the motorcycle To apply the rear bra...

Page 30: ...hich will revert the system to conven tional braking if a malfunction occurs TIP 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 applied...

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

Page 32: ...to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use premium unleaded gas oline with a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce mainte nance costs Gasohol There are two types of gasohol gaso...

Page 33: ...tem is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before doing any maintenance work Do not allow the engine to idle more than a few...

Page 34: ...properly se cured before riding EAUM3640 Helmet holding cable A helmet holding cable is located un der the seat Use this cable in conjunc tion with the screwdriver to secure a helmet to the vehicle To secure a helmet with the helmet holding cable 1 Remove the seat See page 3 19 2 Remove the screwdriver from its holders by pulling it up from the left side and then remove the hel met holding cable f...

Page 35: ... holder since the helmet may hit objects causing loss of control and possibly an accident EWA10162 To release a helmet from the helmet holding cable 1 Remove the seat 2 Remove the screwdriver then re move the helmet holding cable from the helmet 3 Store the cable under the seat by hooking the cable loops over the screwdriver install the screw driver in its original position and then place the helm...

Page 36: ... kit to make the adjustment WARNING EWA10222 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 to exc...

Page 37: ... off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU57950 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following f...

Page 38: ...d 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the side of the start engine stop 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 unt...

Page 39: ...rol functions 3 24 3 EAU70640 Auxiliary DC connector This vehicle is equipped with an auxil iary DC connector Consult your Yamaha dealer before installing any accessories UB34E0E0 book Page 24 Friday July 10 2015 10 31 AM ...

Page 40: ...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 3 16 3 18 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessa...

Page 41: ...ttle grip free play and lubricate ca ble and grip housing 6 15 6 25 Control cables Make sure that operation is smooth Lubricate if necessary 6 25 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 23 6 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 16 6 18 Brake and shift pedals Make ...

Page 42: ... 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 3 22 ITEM CHECKS PAGE UB34E0E0 book Page 3 Friday July 10 2015 10 31 AM ...

Page 43: ...ch an engine auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU69870 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 clutch lever pul...

Page 44: ...3 4 for the warning light circuit check 2 Shift the transmission into the neutral position The neutral indi cator light should come on If not ask a Yamaha dealer to check the electrical circuit 3 Start the engine by sliding the switch toward If the engine fails to start release the start engine stop switch wait a few seconds and then try again Each starting attempt should be as short as possible t...

Page 45: ...he clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU58270 To decelerate 1 Release the throttle and apply both the front and the rear brakes smoothly to slow the motorcycle 2 At the recommended shift points shown in the following table shift to a lower gear 3 When the motorcycle...

Page 46: ...n 0 and 1600 km 1000 mi For this reason you should read the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be a...

Page 47: ...cle EAU17214 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10312 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass...

Page 48: ... 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 3 for more in formation about carbon monox ide WARNING EWA15461 Brake discs calipers d...

Page 49: ...r 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 ZAUM1374 1 UB34E0E0 book Page 2 Friday July 10 ...

Page 50: ...amaha dealer as they require special tools data and tech nical skills EAU46911 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 ...

Page 51: ...and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 6 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 7 Brake fluid Change Every 2 years 8 Wheels Check runout and for damage 9 Tires Check tread depth and for...

Page 52: ...ed grease Every 20000 km 12000 mi 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lithium soap based grease 17 Clutch lever pivot shaft Lubricate with lithium soap based grease 18 Shift pedal pivot shaft Lubricate with lithium soap based grease 19 Sidestand Check...

Page 53: ...tridge Replace 26 Cooling system Check coolant level and vehicle for coolant leakage Change coolant Every 3 years 27 Front and rear brake switches Check operation 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 30 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHE...

Page 54: ...ir 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 UB34E0E0 book Page 7 Friday J...

Page 55: ... excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads TIP If a torque wrench is not available when installing a spark plug a good esti...

Page 56: ... 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 left side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the...

Page 57: ...er 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 filte...

Page 58: ...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 light should go off NOTICE ECA20860 If the oil pressure warning light flick ers or remains on even if the oil level is correct immediately turn the en gine off and have a Yamaha de...

Page 59: ...minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove the reservoir cap WARNING Re move only the coolant reservoir cap Never attempt to remove the radiator cap when the en gine is hot EWA15162 4 Add coolant to the maximum level mark and then install the reservoir cap NOTICE If coolant is not available use distilled water or soft tap water instead Do not use ...

Page 60: ...e the coolant reservoir cov er by removing the bolt and quick fastener and then remove the coolant reservoir 5 Remove the coolant reservoir cap 6 Drain the coolant from the coolant reservoir by turning it upside down 7 Install the coolant reservoir and its cover by placing them in the origi nal position and then installing the bolt and quick fastener Coolant reservoir capacity up to the maximum le...

Page 61: ...nt coolant until it reaches the top of the radi ator and then install the radiator cap and radiator cap retaining bolt 16 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 17 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling...

Page 62: ...k hose can be easily reached and should be frequently checked and cleaned if necessary To clean the air filter check hose 1 Remove the air filter check hose under the air filter case 2 Clean and then install the hose EAU21385 Checking the throttle grip free play The throttle grip free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the inner edge of the throttle grip Periodi cally check the thrott...

Page 63: ...nd 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 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total wei...

Page 64: ...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 information This model is equipped with tubeless tires and rubber tire air valves Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and...

Page 65: ... for approximately 100 km 60 mi after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions EAU21963 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warp age o...

Page 66: ... at the crank case 3 To increase the clutch lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in di rection b 4 Tighten the locknut EAU37914 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA1421...

Page 67: ...ear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU36891 Front brake pads Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying t...

Page 68: ...ng the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if necessary Front brake Rear brake WARNING EWA16011 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may al low air to enter the brake sys tem reducin...

Page 69: ...As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EAU22733 Changing the brake fluid Have a Yamaha ...

Page 70: ...adjust the drive chain slack Consult a Yamaha dealer before ad justing the drive chain slack 1 Loosen the locknut at each end of the swingarm and then loosen the axle nut 2 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear ...

Page 71: ...on chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high...

Page 72: ...vent unsafe condi tions EWA10712 EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though t...

Page 73: ...pedal pivots should be lu bricated if necessary Brake pedal Shift pedal EAU23144 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease UB34E0E0 book Page 26 Friday July 10 2015 10 31 AM ...

Page 74: ... it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAU23252 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap ba...

Page 75: ...ner 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 smoothly...

Page 76: ...odic 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 EAUM3750 Battery This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tight ened WA...

Page 77: ...ttery tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories 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 ...

Page 78: ...ways keep the battery charged Storing a discharged battery can cause permanent battery damage 5 Place the battery cover in the orig inal position and then install the bolts 6 Install the diagnostic connector by pushing it downward 7 Install the seat holder by installing the bolts and then tighten the bolts to the specified torque EAUM3670 Replacing the fuses The main fuse and the fuse boxes are lo...

Page 79: ...f a higher amperage 1 Diagnostic connector 2 Bolt 1 Battery cover ZAUM1378 2 1 ZAUM1387 1 1 Starter relay cover 2 Fuse box 3 Spare main fuse 4 Main fuse ZAUM1380 2 3 4 1 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Fuel injection system fuse 5 Backup fuse for clock and immobilizer sys tem 6 Radiator fan motor fuse 7 ABS solenoid fuse 8 ABS motor fuse 9 Parking lighting fuse 10 Auxili...

Page 80: ...TICE ECA10651 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do ...

Page 81: ...headlight bulb into position and then secure it with the bulb holder 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the bolts 7 Have a Yamaha dealer adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb 1 Bolt ZAUM1381 1 1 Headlight bulb cover 2 Headlight coupler 1 Headlight bulb holder 2 Headlight bulb ZAUM138...

Page 82: ...ing it out 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 pushing it in 6 Install the headlight unit EAU24182 Tail brake light This model is equipped with an LED type tail brake light If the tail brake light does not come on have a Yamaha dealer check it 1 Auxiliary light bulb socket ZAUM1384 1 1 Auxiliary light bulb...

Page 83: ...into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11192 EAU24331 License plate light If the license plate light does not come on have a Yamaha dealer check the electrical circuit or replace the bulb 1 Turn signal light lens 2 Screw 1 2 1 Turn signal light bulb 1 UB34E...

Page 84: ... 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 85: ...riodic maintenance and adjustment 6 38 6 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UB34E0E0 book Page 38 Friday July 10 2015 10 31 AM ...

Page 86: ... Have a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The engine does not st...

Page 87: ...hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended cool ant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check t...

Page 88: ...utlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Alwa...

Page 89: ...ild 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 corros...

Page 90: ...x 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 EAU26183 Sto...

Page 91: ...the engine over EWA10952 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively tu...

Page 92: ...th oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 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 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline Gasohol E10 acceptable Fuel tank capacity 14 0 L 3 70 US gal 3 08 Imp gal Fue...

Page 93: ...heel Wheel type Cast wheel Rim size 17M C x MT5 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 operation Specified brake fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 130 mm 5 1 in Rear suspension Type Swingarm link suspension Spr...

Page 94: ...ight LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuse Main fuse 30 0 A Auxiliary fuse 2 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Parking lighting fuse 7 5 A Radiator fan motor fuse 10 0 A Fuel injection system fuse 10 0 A ABS control unit fuse 7 5 A ABS motor fuse 30 0 A ABS solenoid fuse 20 0 A Backup fuse 7 ...

Page 95: ... MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26442 Engine serial number The engine serial number is st...

Page 96: ...Re cord the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer EAU69910 Diagnostic connector The diagnostic connector is located as shown 1 Diagnostic connector ZAUM1370 1 UB34E0E0 book Page 2 Friday July 10 2015 10 31 AM ...

Page 97: ...18 Fuel tank cap 3 16 Fuses replacing 6 31 H Handlebar switches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 33 Helmet holding cable 3 19 High beam indicator light 3 4 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Indicator lights and warning lights 3 4 L License plate light 6 36 M Main switch ...

Page 98: ...eshooting charts 6 39 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 36 Turn signal switch 3 13 V Valve clearance 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheels 6 18 UB34E0E0 book Page 2 Friday July 10 2015 10 31 AM ...

Page 99: ...UB34E0E0 book Page 3 Friday July 10 2015 10 31 AM ...

Page 100: ...PRINTED IN FRANCE 2015 09 E PANTONE285C MBK Industrie Z I de Rouvroy 02100 Saint Quentin Original instructions ...

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Yamaha XSR MTM690, Owner'S Manual

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