Yamaha XTZ690 Owner'S Manual Download

Page: 71 / 102

Perio

ic maintenance an

justment

6-20

TIP

If the specified clutch lever free play
cannot be obtained as described
above, proceed as follows.

1. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loos-
en the clutch cable.

2. Loosen the locknut 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

Checkin

the

rake lever free

play

There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.

WARNING

EWA14212

A soft or spon

y feelin

in the

rake

lever can in

icate the presence of

air in the hy

raulic system. If there is

air in the hy

raulic system, have a

Yamaha

ealer

lee

the system

fore operatin

the vehicle. Air in the

raulic system will

iminish the

rakin

performance, which may re-

sult in loss of control an

an acci-

ent.

1. Locknut
2. Clutch lever free play adjusting nut

(b)

(a)

1. No brake lever free play

UBW3E0E0.book Page 20 Friday, May 24, 2019 11:01 AM

Summary of Contents for XTZ690

Page 1: ...PANTONE285C XTZ690 XTZ690 U OWNER S MANUAL BW3 F8199 E0 Read this manual carefully before operating this vehicle English E ...

Page 2: ...ective 2014 53 EU The full text of the EU declaration of conformity is available at the following internet address https global yamaha motor com eu_doc Frequency band 134 2 kHz The maximum radio frequency power 49 0 dBμV m Manufacturer YAMAHA MOTOR ELECTRONICS Co Ltd 1450 6 Mori Mori machi Shuchi Gun Shizuoka 437 0292 Japan Importer YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk 1...

Page 3: ...nd 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 most...

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: ...U OWNER S MANUAL 2019 by MBK INDUSTRIE 1st edition July 2019 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France UBW3E0E0 book Page 2 Friday May 24 2019 11 01 AM ...

Page 6: ...maintenance and adjustment 6 1 Tool kit 6 2 Periodic maintenance charts 6 3 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 5 Removing and installing cowlings 6 9 Checking the spark plugs 6 9 Canister 6 10 Engine oil and oil filter cartridge 6 11 Why Yamalube 6 14 Coolant 6 14 Replacing the air filter element and cleaning the check hose 6 ...

Page 7: ...light 6 33 Replacing a turn signal light bulb 6 33 License plate light 6 34 Supporting the motorcycle 6 34 Troubleshooting 6 35 Troubleshooting chart 6 36 Motorcycle care and storage 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 Specifications 8 1 Consumer information 9 1 Identification numbers 9 1 Diagnostic connector 9 2 Vehicle data recording 9 2 Index 10 1 UBW3E0E0 book Page 2 Friday May 24...

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: ...ould 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 Protective Apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The us...

Page 10: ... 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 cargo must not exceed the maximum load limit Operation of an overloaded vehicle could cause an accident When loading within this weight limit keep the following in mind Carg...

Page 11: ...n 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 Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control opera tion or obscure lights or reflec tors ...

Page 12: ... 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 the motorcycle with tie downs or suitable straps that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not...

Page 13: ...age 6 10 4 Seat lock page 3 19 5 Shock absorber assembly spring preload adjusting knob page 3 23 6 Shift pedal page 3 14 7 Engine oil drain bolt page 6 11 8 Engine oil level check window page 6 11 9 Engine oil filter cartridge page 6 11 10 Front fork compression damping force adjusting screw page 3 21 UBW3E0E0 book Page 1 Friday May 24 2019 11 01 AM ...

Page 14: ...21 Right view 1 2 3 4 5 6 1 Main fuse page 6 31 2 Fuse box page 6 31 3 Battery page 6 30 4 Fuel tank cap page 3 16 5 Brake pedal page 3 15 6 Rear brake fluid reservoir page 6 22 UBW3E0E0 book Page 2 Friday May 24 2019 11 01 AM ...

Page 15: ...ndlebar switches page 3 12 3 Auxiliary DC jack page 3 26 4 Multi function meter unit page 3 5 5 Front brake fluid reservoir page 6 22 6 Right handlebar switches page 3 12 7 Brake lever page 3 15 8 Throttle grip page 6 17 9 Main switch steering lock page 3 2 UBW3E0E0 book Page 3 Friday May 24 2019 11 01 AM ...

Page 16: ...ep the standard keys as well as keys of other immobilizer systems away from the code re registering key Keep other immobilizer system keys away from the main switch as they may cause signal interfer ence NOTICE ECA11823 DO NOT LOSE THE CODE RE REG ISTERING KEY CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST If the code re registering key is lost the existing standard keys can still be used to start ...

Page 17: ...ight will stay on until the key is turned to OFF even if the engine stalls EAU10662 OFF All electrical systems are off The key can be removed WARNING EWA10062 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU1068B LOCK The steering is locked and all electrical systems are off Th...

Page 18: ...nsmission is in the neutral position EAU11081 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU59963 Oil pressure warning light This warning light comes on if the en gine oil pressure is low TIP When the vehicle is turned on the light should come on go off briefly and then remain on until the engine is start ed Otherwise have a Yamaha de...

Page 19: ...or other vehicle control system If this occurs have a Yamaha dealer check the on board diagnostic system TIP When the vehicle is turned on the light will come on for a few seconds and then go off If the light does not come on or if the light remains on have a Yamaha dealer check the vehicle EAU69895 ABS warning light This warning light comes on when the vehicle is first turned on and goes off afte...

Page 20: ...bilizer system indicator light flashes in the pattern slowly 5 times then quickly 2 times this could be caused by transponder inter ference If this occurs try the following 1 Make sure there are no other im mobilizer keys close to the main switch Other immobilizer system keys may cause signal interfer ence and prevent the engine from starting 2 Use the code re registering key to start the engine 3...

Page 21: ...ARNING EWA12423 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer shows the engine speed NOTICE ECA23050 Do not operate the engine in the ta chometer high r min zone High ...

Page 22: ...ndicator This indicator comes on when the vehi cle is being operated in an environ mentally friendly fuel efficient manner The indicator goes off when the vehicle is stopped TIP Consider the following tips to reduce fuel consumption Avoid high engine speeds during acceleration Travel at a constant speed Select the transmission gear that is appropriate for the vehicle speed Transmission gear displa...

Page 23: ...icle being stationary push the OFF ROAD ABS ON OFF button until the ABS OFF warn ing light starts flashing then re lease the button 3 The ABS OFF warning light and OFF ROAD indicator will come on simultaneously TIP The ABS will be disabled until the key is turned to OFF or the engine stop switch is turned to stop when the engine is running or you stop the vehicle and push the OFF ROAD ABS ON OFF b...

Page 24: ...e bottom set button until it is reset If you do not reset the fuel reserve tripmeter manually it will reset au tomatically and disappear from the display after refueling and traveling 5 km 3 mi Fuel reserve tripmeter When the fuel level becomes low the last segment of the fuel meter will start flashing The fuel reserve tripmeter TRIP F will automatically appear and start counting the distance trav...

Page 25: ...he fuel con sumption under current riding condi tions The instantaneous fuel consumption display can be set to either km L L 100 km when using kilometers To switch the the fuel consumption units push the top set button until the measurement units change When us ing miles the fuel consumption unit is MPG km L The distance that can be traveled on 1 0 L of fuel under the current riding conditions is ...

Page 26: ... select it and while the digits flash push the bottom set button until it is reset TIP After resetting the average fuel con sumption _ _ _ will be shown until the vehicle has traveled 1 km 0 6 mi Coolant temperature This display shows the coolant tem perature from 40 C to 116 C in 1 C increments If the message Hi flashes stop the vehicle then stop the engine and let it cool See page 6 37 TIP When ...

Page 27: ... button until the display switches to the bright ness control mode 4 Push the bottom set button to set the brightness level 5 Push the top set button to confirm the selected brightness level and exit the brightness control mode TIP There are 6 brightness level settings EAU1234M Handlebar switches Left 1 Brightness level display 1 1 Hazard switch 2 Pass switch PASS 3 Dimmer switch 4 Turn signal swi...

Page 28: ...ne stop switch Set this switch to run before starting the engine Set this switch to stop to stop the engine in case of an emergency such as in the event of an overturn or if the throttle is stuck EAU12713 Start switch Push this switch to crank the engine with the starter See page 5 2 for start ing instructions prior to starting the en gine EAU12735 Hazard switch With the key in the ON or posi tion...

Page 29: ...r to engage the clutch and transmit power to the rear wheel TIP The lever should be pulled rapidly and released slowly for smooth shifting See page 5 3 EAU12876 Shift pedal The shift pedal is located on the left side of the motorcycle To shift the transmission to a higher gear move the shift pedal up To shift the trans mission to a lower gear move the shift pedal down See page 5 3 1 Clutch lever 1...

Page 30: ...system ABS acts on the front and rear brakes indepen dently WARNING EWA16051 Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS The ABS performs best with long braking distances On certain surfaces such as rough or gravel roads the brak ing distance may be longer with the ABS than without How to operate the brakes Operate the brake lever and brake peda...

Page 31: ...s ride on paved roads with the ABS turned on Riding on public roads with the ABS disabled may be illegal and void your insurance Turn the ABS off only when riding on non paved surfaces EAUM1794 Fuel tank cap To remove the fuel tank cap 1 Open the fuel tank cap lock cover 2 Insert the key into the lock and turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed To ...

Page 32: ... 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 fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel...

Page 33: ...regular unleaded gaso line with a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that con taining methanol Gasohol containing ethanol can be used if the ethanol con ten...

Page 34: ...The exhaust system 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 ...

Page 35: ...he bolts with the hexa gon wrench 3 Lift the rear of the rider seat and pull it backward To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then place the seat in the original position 2 Install the bolts with the hexagon wrench 3 Insert the hexagon wrench back into its holder on the rider seat 4 Install the passenger seat TIP Make su...

Page 36: ...mpression damping force ad justing screws NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Rebound damping force Turn the adjusting screw in direction a to increase the rebound damping force Turn the adjusting screw in direction b to decrease the rebound damping force To set the rebound damping force turn the adjuster in direction a unti...

Page 37: ...ection a until it stops and then count the clicks in direction b 3 Install the rubber cap TIP When turning the damping force adjuster in direction a the 0 click position and the 1 click position may be the same When turning the damping force adjuster in direction b it may click beyond the stated specifica tions however such adjustments are ineffective and may damage the suspension 1 Rubber cap 1 1...

Page 38: ...vehicle 2 Remove the bleed screws and al low all of the air to escape from each fork leg 3 Install the bleed screws 4 Lower the front wheel so that it is on the ground and then put the sidestand down EAUM4120 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust er and rebound and compression damping force adjusters NOTICE ECA10102 To avoid dam...

Page 39: ...ction a the 0 click position and the 1 click position may be the same When turning the damping force adjuster in direction b it may click beyond the stated specifica tions however such adjustments are ineffective and may damage the suspension Compression damping force Turn the adjuster in direction a to in crease the compression damping force Turn the adjuster in direction b to de crease the compr...

Page 40: ...amper 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 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 as sembly yourself Take the shock ab...

Page 41: ...ccesso ries that require more than the stated capacity at any one time This may overload the circuit and cause the fuse to blow TIP To prevent battery drain do not use an accessory with the engine off Auxiliary DC jack A 12 V accessory with the proper con nector can be used when the main switch is on To use the auxiliary DC jack 1 Turn the vehicle power off 2 Remove the auxiliary DC jack cap 3 Tur...

Page 42: ...ft side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situa tions See the following section for an explanation of the ignition circuit cut off system WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the side...

Page 43: ...ne starts unless the clutch lever is pulled and the sidestand is up Also it will stop the running engine should the sidestand be lowered while the trans mission is in gear Periodically check the system via the following procedure TIP This check is most reliable if per formed with a warmed up engine See pages 3 2 and 3 12 for switch operation information UBW3E0E0 book Page 28 Friday May 24 2019 11 ...

Page 44: ... has stalled 10 Move the sidestand up 11 Pull the clutch lever 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not be working The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working The motorcycle should not be ridden until checked by a Yamaha dealer The sidest...

Page 45: ...wing points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather overflow hose for obstructions cracks or damage and check hose connection 3 17 3 19 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 necessary a...

Page 46: ...ttle grip free play and lubricate ca ble and grip housing 6 17 6 26 Control cables Make sure that operation is smooth Lubricate if necessary 6 26 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 23 6 25 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 19 Brake and shift pedals Make ...

Page 47: ... 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 27 ITEM CHECKS PAGE UBW3E0E0 book Page 3 Friday May 24 2019 11 01 AM ...

Page 48: ...st 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above 5000 r min NOTICE After 1000 km 600 mi of operation the engine oil must be changed and the oil filt...

Page 49: ...ove have a Yamaha dealer check the vehicle 3 Shift the transmission into the neutral position 4 Start the engine by pushing the start switch 5 Release the start switch when the engine starts or after 5 seconds Wait 10 seconds before pressing the switch again to allow battery voltage to restore NOTICE ECA11043 For maximum engine life never ac celerate hard when the engine is cold EAUM3632 TIP This ...

Page 50: ...d accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 After starting out close the throt tle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmiss...

Page 51: ... riding style Consider the follow ing tips to reduce fuel consumption Shift up swiftly and avoid high en gine speeds during acceleration Do not rev the engine while shift ing down and avoid high engine speeds with no load on the en gine 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 EAU17214 Parking Whe...

Page 52: ... 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 EWA15461 Brake discs calipers d...

Page 53: ...his manual and the tools provided in the tool kit are intended to assist you in the perfor mance of preventive maintenance and minor repairs However a torque wrench and other tools are necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have your Yamaha dealer perform it for you 1 Tool kit 2 Storage pouch 1 2 UBW3E0E...

Page 54: ...ad EAU71051 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 Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 40000 km ...

Page 55: ... control system Check control system for dam age Replace if necessary 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 UBW3E0E0 book Page 4 Friday May 24 2019 11 01 AM ...

Page 56: ...filter case check hose Clean 4 Clutch Check operation Adjust 5 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 6 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 7 Brake hoses Check for cracks or damage Replace Every 4 years 8 Brake fluid Change Every 2 years 9 Wheels Check runout spoke tightness and for dama...

Page 57: ...as 14 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Brake lever pivot shaft Lubricate with silicone grease 17 Brake pedal pivot shaft Lubricate with lithium soap based grease 18 Clutch lever pivot shaft Lubricate with lithium soap based grease 19 Shift...

Page 58: ...m and con necting arm pivoting points Check operation 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter car tridge Replace 27 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate NO ITEM CHECK OR MAINTENANCE JOB ODO...

Page 59: ...Every two years replace the internal components of the brake master cylinders and change the brake fluid Replace the brake hoses every four years or sooner if cracked or damaged 30 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Lights signals and switches Check operation Adjust headlig...

Page 60: ...e any spark plug to slowly erode they should be removed and checked in accordance with the peri odic maintenance and lubrication chart In addition the condition of the spark plugs can reveal the condition of the engine The porcelain insulator around the center 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 instal...

Page 61: ... coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU36112 Canister This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before o...

Page 62: ...he oil level through the engine oil level check window 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the maximum level mark TIP Check the O ring for damage and re place it if necessary To change the engine oil and re place the filter 1 Place the vehicle on a level sur face 2 Remove cowling A See page 6 9 3 Start the engine warm it up...

Page 63: ... new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 9 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque 10 Refill with the specified amount of the recommended engine oil 1 Engine oil drain bolt 2 Gasket 1 Oil filter cartridge 2 Oil filter wrench 1 2 1 2 1 O ring 1 Torque wrench Tig...

Page 64: ...ngine 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 dea...

Page 65: ...hecked regularly In addition the coolant must be changed at the intervals specified in the periodic maintenance chart TIP If genuine Yamaha coolant is not avail able use an ethylene glycol antifreeze containing corrosion inhibitors for alu minum engines and mix with distilled water at a 1 1 ratio EAU20097 To check the coolant level Since the coolant level varies with en gine temperature check when...

Page 66: ...changed at the in tervals specified in the periodic main tenance and lubrication chart Have a Yamaha dealer change the coolant WARNING Never attempt to remove the radiator cap when the engine is hot EWA10382 EAUM4160 Replacing the air filter ele ment and cleaning the check hose The air filter element must be replaced at the intervals specified in the periodic maintenance chart Replace the air fil ...

Page 67: ...cure it with the screw NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operat ed without the air filter element installed otherwise the pis ton s and or cylinder s may become excessively worn ECA10482 6 Install the air filter case cover by installing the screws 7 Install the seats To clean the air filter check hose 1 Remove the air ...

Page 68: ...ne is cold EAU88380 Tires Tires are the only contact between the vehicle and the road Safety in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjust...

Page 69: ...ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal cha...

Page 70: ...seness If any loose spokes are found have the wheel adjusted by your Yamaha dealer Improperly tight ened spokes can cause wheel misalignment Have the wheel balanced whenev er the tire or tube has been re placed An unbalanced wheel can result in adverse handling charac teristics and shortened tire life WARNING EWA10611 The wheels on this model are not designed for use with tubeless tires Do not att...

Page 71: ...ghten the locknut EAU37914 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or 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 ...

Page 72: ... indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU46292 Rear brake pads Each rear brake pad is provided with wear indicator grooves whi...

Page 73: ...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 or dust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit valves NOTICE ECA17641 Brake fluid may damage pain...

Page 74: ...g Brake seals every 2 years Brake hoses every 4 years EAU22762 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU60046 To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neutral position 3 Push...

Page 75: ...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 wheel for ward TIP Using the alignment marks on each side of...

Page 76: ...10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11122 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special...

Page 77: ...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 the cover is installed correctly it does not completely protect the cable from wa ter entry Therefore use care not to pour water directly ont...

Page 78: ...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 Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease UBW3E0E0 book Page 27 Friday May 24 2019 11 01 AM ...

Page 79: ...he 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 EAUM1653 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic ma...

Page 80: ...al times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23285 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the periodic maintenance and...

Page 81: ...tains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batte...

Page 82: ...be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure to turn the main switch off then con nect the positive lead before connecting the negative lead ECA16842 4 After installation make sure that the battery leads are properly con nected to the battery terminals N...

Page 83: ...e a Yamaha dealer check the electrical system 1 ABS solenoid fuse 2 ABS motor fuse 3 Parking lighting fuse 4 Accessory fuse 5 Auxiliary fuse 6 ABS control unit fuse 7 Ignition fuse 8 Signaling system fuse 9 Headlight fuse 10 Fuel injection system fuse 11 Backup fuse for clock and immobilizer sys tem 12 Radiator fan motor fuse 13 Spare fuse 8 9 7 1 2 3 4 5 6 10 11 12 13 13 Specified fuses Main fuse...

Page 84: ... any type of tinted film or stickers to the headlight lens 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 EAU24205 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 1 Turn ...

Page 85: ...e the bulb EAUM4210 Supporting the motorcycle Since this model is not equipped with a centerstand use a motorcycle jack when removing the front or rear wheel or when performing other maintenance that requires the motorcycle to stand upright To elevate the vehicle 1 Remove cowling A See page 6 9 2 If necessary insert a piece of wood between the motorcycle jack and the engine crankcase Then lift the...

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

Page 87: ...ve a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug s Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Dry Wet Try sta...

Page 88: ...stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended cool ant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system f...

Page 89: ... may be sprayed with salt as a de icing method This salt can stay on the roads well into spring so be sure to wash the underside and chassis parts after riding in such areas Genuine Yamaha care and main tenance products are sold under the YAMALUBE brand in many markets worldwide See your Yamaha dealer for addi tional cleaning tips NOTICE ECA26280 Improper cleaning can cause cos metic and mechanica...

Page 90: ...ush for hard to reach places NOTICE Use cold water if the vehicle has been exposed to salt Warm wa ter will increase salt s corrosive properties ECA26301 3 For windshield equipped vehicles Clean the windshield with a soft towel or sponge dampened with water and a pH neutral detergent If necessary use a high quality windshield cleaner or polish for motorcycles NOTICE Never use any strong chemicals ...

Page 91: ...minants left on the brakes or tires can cause loss of control Make sure there is no lubricant or wax on the brakes or tires If necessary wash the tires with warm water and a mild deter gent If necessary clean the brake discs and pads with brake cleaner or acetone Before riding at higher speeds test the vehicle s braking per formance and cornering behav ior EAU83472 Storage Always store the vehicle...

Page 92: ...This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 7 Lubricate all co...

Page 93: ...O standard MA Engine oil quantity Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 Imp qt With 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 Fuel Recommended fuel Unleaded gasoline E10 acceptable Octane number RON ...

Page 94: ...ake Type Hydraulic dual disc brake Rear brake Type Hydraulic single disc brake Front suspension Type Telescopic fork Rear suspension Type Swingarm link suspension Electrical system System voltage 12 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light 10 0 W 2 Rear turn signal light 10 0 W 2 Auxiliary light LED License pl...

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

Page 96: ... and for research statisti cal analysis and development purpos es Although the sensors and recorded data will vary by model the main data points are Vehicle status and engine perfor mance data Fuel injection and emission relat ed data This data will be uploaded only when a special Yamaha diagnostic tool is at tached to the vehicle such as when maintenance checks or service proce dures are performe...

Page 97: ...ces related to the han dling of vehicle data Even in this case Yamaha will require the contractor to properly handle the vehicle data we provided and Yamaha will appropriate ly manage the data With the consent of the vehicle owner Where obligated by law For use by Yamaha in litigation When the data is not related to an individual vehicle nor owner UBW3E0E0 book Page 3 Friday May 24 2019 11 01 AM ...

Page 98: ...rk adjusting 3 21 Front fork bleeding 3 23 Front fork checking 6 29 Fuel 3 17 Fuel consumption tips for reducing 5 4 Fuel tank cap 3 16 Fuel tank overflow hose 3 19 Fuses replacing 6 31 H Handlebar switches 3 12 Hazard switch 3 13 Headlight beams adjusting 3 21 High beam indicator light 3 3 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 28 Immobilizer system 3 1 Im...

Page 99: ...g 6 17 Tires 6 17 Tool kit 6 2 Troubleshooting 6 35 Troubleshooting chart 6 36 Turn signal indicator lights 3 3 Turn signal light bulb replacing 6 33 Turn signal switch 3 13 V Valve clearance 6 17 Vehicle identification number 9 1 Vehicle lights 6 33 W Wheel bearings checking 6 30 Wheels 6 19 Y Yamalube 6 14 UBW3E0E0 book Page 2 Friday May 24 2019 11 01 AM ...

Page 100: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 101: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 102: ...PRINTED IN FRANCE 2019 07 E PANTONE285C MBK Industrie Z I de Rouvroy 02100 Saint Quentin SAS au capital de 14 000 000 Original instructions ...

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Yamaha XTZ690, Owner'S Manual

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