Yamaha YZF-R3 Owner'S Manual Download Page 72 | Manualshive

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Perio

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ic maintenance an

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a

d

justment

7-24

7

EAU23026

Cleanin

g

an

d

lu

b

ricatin

g

the

d

rive chain

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

NOTICE

ECA10584

The

d

rive chain must

b

e lu

b

ricate

d

after washin

g

the motorcycle, ri

d

in

g

in the rain or ri

d

in

g

in wet areas.

1. Clean the drive chain with kero-

sene and a small soft brush.

NOTICE:

To prevent

d

ama

g

in

g

the O-rin

g

s,

d

o not clean the

d

rive chain with steam cleaners,

hi

g

h-pressure washers or inap-

propriate solvents.

[ECA11122]

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive

chain with a special O-ring chain
lubricant.

NOTICE:

Do not use

en

g

ine oil or any other lu

b

ri-

cants for the

d

rive chain, as they

may contain su

b

stances that

coul

d

d

ama

g

e the O-rin

g

s.

[ECA11112]

EAU23098

Checkin

g

an

d

lu

b

ricatin

g

the

ca

b

les

The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it.

WARNING! Dama

g

e to the

outer housin

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of ca

b

les may result

in internal rustin

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an

d

cause inter-

ference with ca

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le movement. Re-

place

d

ama

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e

d

ca

b

les as soon as

possi

b

le to prevent unsafe con

d

i-

tions.

[EWA10712]

Recommen

d

e

d

lu

b

ricant:

Yamaha cable lubricant or other
suitable cable lubricant

UB0220E0.book Page 24 Tuesday, March 3, 2015 9:20 AM

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Summary of Contents for YZF-R3

Page 1: ...DIC183 YZFR3AF OWNER S MANUAL Read this manual carefully before operating this vehicle B02 F8199 20 English E ...

Page 2: ...EAU46091 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB0220E0 book Page 1 Tuesday March 3 2015 9 20 AM ...

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

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: ...Indonesia Motor Manufacturing 1st edition April 2015 All rights reserved Any reprinting or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufac turing is expressly prohibited Printed in Indonesia UB0220E0 book Page 2 Tuesday March 3 2015 9 20 AM ...

Page 6: ...er s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Checking the spark plugs 7 8 Engine oil and oil filter cartridge 7 9 Coolant 7 12 Replacing the air filter element and cleaning the check hose 7 13 Checking the throttle grip free play 7 15 Valve clearance 7 15 Tires 7 15 Cast wheels 7 17 Adjusting the clutch lever free pl...

Page 7: ... plate light bulb 7 34 Supporting the motorcycle 7 35 Troubleshooting 7 36 Troubleshooting charts 7 37 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Motorcycle noise regulation for Australia 10 2 Index 11 1 UB0220E0 book Page 2 Tuesday March 3 2015 9 20 AM ...

Page 8: ...hicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 4 UB0220E0 book Page 1 Tuesday March 3 2015 9 20 AM ...

Page 9: ...WNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 1TP 2118K A1 STATIONARY NOISE TEST INFORMATION TESTED 88 dB A AT 5375 r min SILENCINGSYSTEM YAMAHA IDENTIFICATION 2MS 2MS 2118G 10 2 3 B02 2811T 00 E13 39R 00 9667 41R 04 9596 53R 01 0723 78R 03 5085 UB0220E0 book Page 2 Tuesday March 3 2015 9 20 AM ...

Page 10: ...you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks This motorcycle is designed to carry the operator and a passen ger The failure of motorists to detect and recogn...

Page 11: ...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 12: ...ycle 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 cargo ...

Page 13: ... change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per formance of your motorcycle Ca...

Page 14: ...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 15: ...30 3 Owner s tool kit page 7 2 4 Passenger seat lock page 4 17 5 Storage compartment page 4 19 6 Shock absorber assembly spring preload adjusting ring page 4 20 7 Shift pedal page 4 12 8 Engine oil drain bolt page 7 9 9 Engine oil filter cartridge page 7 9 UB0220E0 book Page 1 Tuesday March 3 2015 9 20 AM ...

Page 16: ...ery page 7 28 3 Fuel tank cap page 4 14 4 Headlight page 7 32 5 Engine oil filler cap page 7 9 6 Engine oil level check window page 7 9 7 Brake pedal page 4 13 8 Rear brake light switch page 7 19 9 Rear brake fluid reservoir page 7 20 UB0220E0 book Page 2 Tuesday March 3 2015 9 20 AM ...

Page 17: ... 12 2 Left handlebar switches page 4 11 3 Multi function meter unit page 4 4 4 Main switch steering lock page 4 1 5 Front brake fluid reservoir page 7 20 6 Right handlebar switches page 4 11 7 Throttle grip page 7 15 8 Brake lever page 4 12 UB0220E0 book Page 3 Tuesday March 3 2015 9 20 AM ...

Page 18: ...ne is started and stays on until the key is turned to even if the engine stalls EAU54301 off All electrical systems are off The key can be removed WARNING EWA16371 Never turn the key to or LOCK while the vehicle is moving Other wise the electrical systems will be switched off which may result in loss of control or an accident EAU60860 LOCK The steering is locked and all electrical systems are off ...

Page 19: ...by turning the key to The warning light should come on and remain on until the engine is started If the warning light does not come on initially when the key is turned to have a Yamaha dealer check the elec trical circuit NOTICE ECA21210 If the warning light comes on when the engine is running stop the en gine immediately and check oil level If the oil level is below the minimum level add sufficie...

Page 20: ...ation 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 to ON comes on or flashes while riding does not go off after traveling at a speed of 10 km h 6 mi h or high er The ABS may not work correctly If any of the above occurs have a Yamaha dealer check the s...

Page 21: ...nit Changing settings while riding can distract the operator and increase the risk of an accident The multi function meter unit is equipped with the following a speedometer a tachometer a clock a fuel meter a coolant temperature meter a transmission gear display a multi function display a shift timing indicator light a self diagnosis device TIP Be sure to turn the key to before using the SEL and R...

Page 22: ...Push the SEL button and the minute digits will start flashing 5 Push the RES button to set the minutes 6 Push the SEL button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank When the key is turned to the dis play segments of the fuel meter will sweep once across the fuel level range and then return to the current amount in order to test...

Page 23: ... the vehicle then stop the engine and let the engine cool See page 7 38 NOTICE ECA10022 Do not continue to operate the en gine if it is overheating TIP The coolant temperature varies with changes in the weather and engine load 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 funct...

Page 24: ...following order TRIP F km L or L 100 km AVE_ _ _ km L or AVE_ _ _ L 100 km OIL TRIP ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter select it by push ing the SEL button and then push the RES button for at least one sec ond If you do not reset the fuel reserve trip meter manually it resets itself auto matically and the display returns to the prior mode after refueling and traveling 5 km 3 mi Instanta...

Page 25: ...e distance traveled since it was last reset i e since the last oil change The oil change indicator OIL will flash at the initial 1000 km 600 mi then at 5000 km 3000 mi and every 5000 km 3000 mi thereafter to indicate that the engine oil should be changed After changing the engine oil reset the oil change tripmeter and the oil change indicator To reset them both select the oil change tripmeter and ...

Page 26: ...tays on when activated This set ting is selected when the indi cator light stays on Flash the indicator light flashes when activated This setting is selected when the indicator light flashes four times per second Off the indicator light is deac tivated in other words it does not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SEL button ...

Page 27: ...he indicator light 2 Push the SEL button to confirm the selected engine speed The control mode changes to the brightness setting mode To adjust the brightness 1 Push the RES button to select the desired shift indicator light brightness level 2 Push the SEL button to confirm the selected brightness level The display exits the shift timing light control mode and returns to the standard multi functio...

Page 28: ...the switch in after it has re turned to the center position EAU12501 Horn switch Press this switch to sound the horn EAU12661 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 EAU12713 Start switch Push this switch to crank the engine with the starter...

Page 29: ... switch which is part of the igni tion circuit cut off system See page 4 22 EAU12872 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the f...

Page 30: ...h or gravel roads the brak ing distance may be longer with the ABS than without The ABS is monitored by an ECU which 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 n...

Page 31: ...urn the key counterclockwise to the original position remove it and then close the lock cover TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11092 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Front wheel sensor 2 Front wheel ...

Page 32: ...h since fuel may deteriorate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on...

Page 33: ... sure that the end of each hose is not blocked and clean if necessary Make sure that the end of fuel tank breather hose is positioned out side of the cowling EAU13434 Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10863 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire haza...

Page 34: ...the key in that posi tion lift the rear of the passenger seat and pull it off To install the passenger seat 1 Insert the projections on the front of the passenger seat into the seat holders as shown and then push the rear of the seat down to lock it in place 2 Remove the key Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the center cover by re moving the screws 1 Passenge...

Page 35: ... properly secured before riding EAU62930 Helmet holders The helmet holders are located on the bottom of the passenger seat To secure a helmet to a helmet hold er 1 Remove the passenger seat See page 4 17 2 Attach a helmet to a helmet hold er and then securely install the passenger seat WARNING Nev er ride with a helmet attached to the helmet holder since the hel met may hit objects causing loss of...

Page 36: ...en wash ing the vehicle be careful not to let any water enter the storage compartment WARNING EWA15401 Do not exceed the maximum load of 160 kg 353 lb for the vehicle EAU39672 Rear view mirrors The rear view mirrors of this vehicle can be folded forward or backward for parking in narrow spaces Fold the mir rors back to their original position be fore riding WARNING EWA14372 Be sure to fold the rea...

Page 37: ...reby soften the suspension turn the adjusting ring in direction b Align the appropriate notch in the adjusting ring with the po sition indicator on the shock absorber Use the special wrench and the extension bar included in the owner s tool kit to make the adjustment 3 Install the drive chain guard by in stalling the collars and bolts and then tighten the bolts to the spec ified torque 1 Drive cha...

Page 38: ...xplanation of the ignition circuit cut off system WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfillin...

Page 39: ...ission is in gear and the sidestand is up but the clutch le ver is not pulled It prevents starting when the transmission is in gear and the clutch lever is pulled but the side stand 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 accord ing to the following procedure UB...

Page 40: ...0 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch swit...

Page 41: ...points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or damage and check hose connections 4 15 4 16 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 9 Coolant Check coolant level in reservoir If necessa...

Page 42: ...ttle grip free play and lubricate ca ble and grip housing 7 15 7 25 Control cables Make sure that operation is smooth Lubricate if necessary 7 24 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 22 7 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 15 7 17 Brake and shift pedals Make ...

Page 43: ... tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 21 ITEM CHECKS PAGE UB0220E0 book Page 3 Tuesday March 3 2015 9 20 AM ...

Page 44: ...n 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 EAU67610 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 pulled ...

Page 45: ...ills 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 ECA10261 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The t...

Page 46: ... continue to downshift as necessary 4 Once the motorcycle has stopped the transmission can be shifted into the neutral position The neutral indicator light should come on and then the clutch lever can be released WARNING EWA17380 Improper braking can cause loss of control or traction Al ways use both brakes and apply them smoothly Make sure that the motorcycle and the engine have sufficiently slow...

Page 47: ...arefully 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 EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above 7000 r min NOT...

Page 48: ...nd 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 UB0220E0 book Page 5 Tuesday March 3 2015 9 20 AM ...

Page 49: ... 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 2 3 for more in formation about carbon monox ide WARNING EWA15461 Brake discs calipers d...

Page 50: ... 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 2 O ring 1 2 UB0220E...

Page 51: ...nance 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 sys tem Adjust synchroni...

Page 52: ...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 53: ...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 54: ...oling system Check coolant level and vehicle for coolant leakage Change coolant Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 29 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JO...

Page 55: ...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 UB0220E0 book Page 7 Tuesday ...

Page 56: ...engine could be operating improperly Do not at tempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs of elec trode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the sur...

Page 57: ...ankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Place the vehicle on a level sur face 2 Start the engine warm it up for several minutes and then turn it off 3 Pl...

Page 58: ...e new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque TIP Install the new gasket as shown 1 Oil filter wrench 2 Oil filter cartridge 1 2 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf 1 UB...

Page 59: ...r 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 dealer check the vehicle 11 Turn...

Page 60: ...maximum level marks 3 If the coolant is at or below the minimum level mark remove the left side cowling and coolant res ervoir cover to access the coolant reservoir 4 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15162 NOTICE I...

Page 61: ...ING Never attempt to remove the radiator cap when the engine is hot EWA10382 EAU62650 Replacing the air filter ele ment and cleaning the check hose The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas In addition the air filter check h...

Page 62: ...element installed otherwise the piston s and or cylinder s may become excessively worn ECA10482 5 Install the air filter case cover by installing the screws 6 Install the left side panel by install ing the bolts To clean the air filter check hose 1 Check the hose on the front of the air filter case for accumulated dirt or water 2 If dirt or water is visible remove the hose clean it and then instal...

Page 63: ...ly 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 adjusted before each ride WARNING EWA10504 Opera...

Page 64: ...heel 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 information This model is equipped with tubeless tires and rubber tire air valves Tires age even if th...

Page 65: ...r to the wheel A de formed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life EAU62662 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodicall...

Page 66: ... 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 7 Tighten the locknut at the crank case 8 Install the right side cowling by in stalling the bolts TIP Fit the projections on the cowling into the slots as shown 9 Tighten the locknut at the clutch lever 1 Right side cowling 2 Bolt 2 1 2 2 1 Loc...

Page 67: ...em 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 EAU36504 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking takes effect If necessary have a Y...

Page 68: ... the brake pads as a set EAU36721 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a s...

Page 69: ...ter 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 painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually g...

Page 70: ...ed before each ride and adjusted if necessary EAU22776 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 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU62981 To adjust the...

Page 71: ...within the specified limits ECA10572 TIP Using the alignment marks on each side of the swingarm make sure that both drive chain pullers are in the same position for proper wheel alignment 3 Tighten the axle nut then the lock nuts to their specified torques 4 Make sure that the drive chain pullers are in the same position the drive chain slack is correct and the drive chain moves smoothly 5 Install...

Page 72: ... drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11112 EAU23098 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca ble...

Page 73: ...ubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU44275 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 UB0220E0 book Page 25 Tuesday March 3 201...

Page 74: ...d should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone ...

Page 75: ...ck the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10752 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds...

Page 76: ...hecking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU62521 Battery The battery is located under the rider seat See page 4 17 This model is equipped with a VRLA Valve Regulated ...

Page 77: ...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 it and then place it in a cool dry plac...

Page 78: ...er relay coupler and then slide the cover to its orig inal position 5 Place the tray in its original posi tion and then install the quick fas teners 6 Install the passenger seat Fuse box 1 is located behind the center cover See page 4 17 Fuse box 1 1 Quick fastener 2 Tray 2 1 1 Starter relay cover 2 Starter relay coupler 3 Main fuse 4 Spare main fuse 1 2 3 4 1 Fuse box 1 1 Ignition fuse 2 Signalin...

Page 79: ... dam age to the electrical system and possibly a fire EWA15132 3 Turn the key to and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 1 Spare fuse 2 ABS solenoid fuse 3 ABS motor fuse 1 1 2 3 Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 7 5 A...

Page 80: ...fin gerprints on the headlight bulb using a cloth moistened with al cohol 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 the headlight bulb cover by turning it counterclockwise 2 Disconnect the headlight coupler 3 Unhook the headlight bulb holder and then remove the burnt out b...

Page 81: ...EAU39021 Auxiliary light bulb If the auxiliary light does not come on have a Yamaha dealer check the elec trical circuit or replace the bulb 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 1 UB0220E0 book Page 33 Tuesday March 3 2015 9 20 AM ...

Page 82: ...Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light lens by installing the screw NOTICE Do not overtighten the screw oth erwise the lens may break ECA11192 EAU62670 Replacing the license plate light bulb 1 Remove the mudguard by remov ing the quick fasteners 2 Remove the rear fender lower panel by removing the bolts and screws 1 Turn signal light lens ...

Page 83: ...ring the motorcycle to stand upright Check that the motorcy cle is in a stable and level position be fore starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of th...

Page 84: ...l 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 expensive repair bills WARNING EWA1...

Page 85: ... 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 86: ...ed 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 for le...

Page 87: ...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 88: ...n 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 corrosive in combination with water carry out the f...

Page 89: ...cle dry completely before storing or covering it WARNING EWA11132 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s bra...

Page 90: ... spark plugs and then place the spark plugs on the cylinder head so that the elec trodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder walls 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 ...

Page 91: ...Motorcycle care and storage 8 5 8 TIP Make any necessary repairs before storing the motorcycle UB0220E0 book Page 5 Tuesday March 3 2015 9 20 AM ...

Page 92: ...oil filter cartridge replacement 2 10 L 2 22 US qt 1 85 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator including all routes 0 96 L 1 01 US qt 0 84 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank capacity 14 0 L 3 70 US gal 3 08 Imp gal Fuel r...

Page 93: ... kPa 2 50 kgf cm2 36 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT2 75 Rear wheel Wheel type Cast wheel Rim size 17M C x MT4 00 Front brake Type Single 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 spr...

Page 94: ... beam indicator light LED Oil pressure warning light LED Turn signal indicator light LED Engine trouble warning light LED ABS warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 7 5 A Ignition fuse 15 0 A Radiator fan motor fuse 7 5 A ABS control unit fuse 7 5 A ABS motor fuse 30 0 A ABS solenoid fuse 15 0 A Backup fuse 7 5 A UB0220E0 book Page 3 Tuesday March 3 20...

Page 95: ...UMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION EAU62971 Vehicle identification number The vehicle identification number is stamped into the frame under the pas senger seat See page 4 17 TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped ...

Page 96: ...YSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such de...

Page 97: ...adlight bulb replacing 7 32 Helmet holders 4 18 High beam indicator light 4 2 Horn switch 4 11 I Identification numbers 10 1 Ignition circuit cut off system 4 22 Indicator lights and warning lights 4 2 L Labels location 1 1 License plate light bulb replacing 7 34 Luggage strap holders 4 21 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system ...

Page 98: ...eshooting charts 7 37 Turn signal indicator light 4 2 Turn signal light bulb replacing 7 34 Turn signal switch 4 11 V Valve clearance 7 15 Vehicle identification number 10 1 W Wheel bearings checking 7 28 Wheels 7 17 UB0220E0 book Page 2 Tuesday March 3 2015 9 20 AM ...

Page 99: ...UB0220E0 book Page 3 Tuesday March 3 2015 9 20 AM ...

Page 100: ...DIC183 PRINTED IN INDONESIA 2015 04 E ...

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