Yamaha YZF-R6D Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-41

5. Install the brake hose holder on

each side by installing the bolt and
nut.

6. Tighten the axle bolt to the speci-

fied torque.

TIP

While tightening the axle bolt, hold the
wheel axle with a 19-mm hexagon
wrench to keep it from turning.

7. Tighten wheel axle pinch bolt B,

then pinch bolt A to the specified
torque.

8. Retighten pinch bolt B to the spec-

ified torque.

9. Tap the outer side of the right fork

leg with a rubber mallet to align it
with the end of the wheel axle.

10. Tighten wheel axle pinch bolt D,

then pinch bolt C to the specified
torque.

11. Retighten pinch bolt D to the spec-

ified torque.

12. While applying the front brake,

push down hard on the handlebar
several times to check for proper
fork operation.

Tightening torque:

Brake caliper bolt:

35 Nm (3.5 m·kgf, 25 ft·lbf)

Tightening torque:

Axle bolt:

91 Nm (9.1 m·kgf, 66 ft·lbf)

1. Front wheel axle pinch bolt A
2. Front wheel axle pinch bolt B

3. Front wheel axle pinch bolt C

4. Front wheel axle pinch bolt D

Tightening torque:

Wheel axle pinch bolt:

21 Nm (2.1 m·kgf, 15 ft·lbf)

Tightening torque:

Wheel axle pinch bolt:

21 Nm (2.1 m·kgf, 15 ft·lbf)

U1JS21E0.book Page 41 Friday, August 10, 2012 1:26 PM

Summary of Contents for YZF-R6D

Page 1: ...DIC183 YZF R6D OWNER S MANUAL Read this manual carefully before operating this vehicle 1JS 28199 21 English E ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1JS21E0 book Page 1 Friday August 10 2012 1 26 PM ...

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: ...ntial 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 N...

Page 5: ...NUAL 2012 by Yamaha Motor Co Ltd 1st edition August 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1JS21E0 book Page 2 Friday August 10 2012 1 26 PM ...

Page 6: ... 6 3 Engine break in 6 3 Parking 6 4 PERIODIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing cowlings and panels 7 8 Checking the spark plugs 7 12 Engine oil and oil filter cartridge 7 13 Coolant 7 16 Air filter element 7 19 Checking the engine idling speed 7 19...

Page 7: ...rn signal light bulb 7 37 Replacing the license plate light bulb 7 38 Auxiliary light 7 39 Supporting the motorcycle 7 39 Front wheel 7 40 Rear wheel 7 42 Troubleshooting 7 44 Troubleshooting charts 7 45 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...

Page 8: ...icle 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 4 5 3 1 2 U1JS21E0 book Page 1 Friday August 10 2012 1 26 PM ...

Page 9: ...ire normal pressure should be set as follows Up to 90 kg 198 lbs load FRONT REAR 250 kPa 2 50 kgf cm 36 psi 290 kPa 2 90 kgf cm 42 psi 90kg 198 lbs maximum load FRONT REAR 250 kPa 2 50 kgf cm 36 psi 290 kPa 2 90 kgf cm 42 psi 14B 21668 00 Use PREMIUM unleaded gasoline with min 95 octane RON 2S3 2817K 00 4AA 22259 40 1 2 3 5 4 U1JS21E0 book Page 2 Friday August 10 2012 1 26 PM ...

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 vehicle 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 car ry the operator and a passenger The failure of motorists to detect and recogni...

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: ...cle is changed To avoid the possibility of an accident use ex treme 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: ...ange 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 perfor mance of your motorcycle Care ...

Page 14: ...uc 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 the mot...

Page 15: ...6 Shock absorber assembly compression damping force adjusting bolt for slow compression damping page 4 24 7 Owner s tool kit page 7 2 8 Shock absorber assembly rebound damping force adjusting screw page 4 24 9 Shift pedal page 4 15 10 Engine oil filter cartridge page 7 13 11 Engine oil drain bolt page 7 13 12 Front fork compression damping force adjusting bolt for fast compres sion damping page 4 ...

Page 16: ... injection system fuse page 7 35 6 Battery page 7 33 7 Air filter element page 7 19 8 Coolant reservoir page 7 16 9 Radiator cap page 7 16 10 Engine oil filler cap page 7 13 11 Coolant drain bolt page 7 17 12 Engine oil dipstick page 7 13 13 Brake pedal page 4 16 14 Rear brake light switch page 7 24 15 Rear brake fluid reservoir page 7 25 U1JS21E0 book Page 2 Friday August 10 2012 1 26 PM ...

Page 17: ... 15 2 Left handlebar switches page 4 14 3 Main switch steering lock page 4 2 4 Multi function meter unit page 4 8 5 Front brake fluid reservoir page 7 25 6 Right handlebar switches page 4 14 7 Brake lever page 4 16 8 Throttle grip page 7 19 U1JS21E0 book Page 3 Friday August 10 2012 1 26 PM ...

Page 18: ...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 19: ...fe place and only use it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All e...

Page 20: ...ey in and then turn it to OFF while still pushing it EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an exten...

Page 21: ...el is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11366 Fuel level warning light This warning light...

Page 22: ...s occurs stop the engine immediately and allow the en gine to cool The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit NOTICE ECA10021 Do n...

Page 23: ...g 117 134 C 243 274 F Coolant temperature flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 7 46 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 46 TRIPA C TRIPA C TRIPA C TRIPA C U1JS21E0 book Page 6 Friday August...

Page 24: ...uld come on for a few seconds and then go off If the indicator light does not come on initially when the key is turned to ON or if the indicator light remains on have a Yamaha dealer check the electrical circuit See page 4 11 for a detailed explanation of the function of this indi cator light and on how to set it EAU38624 Immobilizer system indicator light The electrical circuit of the indicator l...

Page 25: ... indicator light control mode TIP Be sure to turn the key to ON before using the SELECT and RESET but tons except for setting the display brightness and shift timing indicator light control mode Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min...

Page 26: ... distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter odome ter and stopwatch modes in the follow ing order F TRIP Stopwatch TRIP A TRIP B ODO F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will r...

Page 27: ...ant TIP When the coolant temperature display is selected C is displayed for one second and then the coolant tempera ture is displayed NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Air intake temperature display The air intake temperature display indi cates the temperature of the air drawn into the air intake duct Push the RE SET button to switch the coolant tem peratu...

Page 28: ...following 1 Use the code re registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one ...

Page 29: ...ing indicator light activity function To adjust the brightness of the multi function meter displays and tachometer 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to ON and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The control mode chang...

Page 30: ... be tween 10000 r min and 18000 r min From 10000 r min to 13000 r min the indicator light can be set in increments of 500 r min From 13000 r min to 18000 r min the in dicator light can be set in incre ments of 200 r min Be sure to set the deactivation function to a higher engine speed than for the activation function otherwise the shift timing indicator light will remain deactivated 1 Push the RES...

Page 31: ...switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU...

Page 32: ...0 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 28 EAU12871 Shift pedal The...

Page 33: ... turn the ad justing knob while holding the lever pushed away from the throttle grip When the desired position is obtained be sure to set it by aligning a groove on the adjusting knob with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 2 Distance between brake lever and thro...

Page 34: ...fuel is a fire hazard EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi ci...

Page 35: ... spills on your clothing change your clothes EAU13391 NOTICE ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage 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 gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a ga...

Page 36: ...haust 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 do ing any maintenance work Do not allow the engine to idle more ...

Page 37: ...To remove the passenger seat 1 Insert the key into the seat lock and then turn it clockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projections on the pas senger seat into the seat holders as shown and then push the front of the seat down to lock it in place 2 Remove the key TIP Make sure that the...

Page 38: ...e and then clip the snap hook onto the cable holder as shown 4 Install the passenger seat WARNING Never ride with a helmet attached to a helmet holding cable since the helmet may hit objects causing loss of control and possibly an acci dent EWA14331 To release a helmet from the helmet holding cable 1 Remove the passenger seat 2 Unfasten the snap hooks from the cable holder and then remove the cabl...

Page 39: ...mpres sion damping force adjusting bolts for fast compression damping and com pression damping force adjusting bolts for slow compression damping NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decr...

Page 40: ...tion b To adjust the compression damping force for slow compression damping To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt on each fork leg in direction a To de crease the compression damping force Spring preload setting Minimum soft 0 Standard 2 Maximum hard 5 1 Rebound damping force adjusting screw 1 a b Rebound damping setting Minim...

Page 41: ...screw a compression damping force adjusting bolt for fast compres sion damping and a compression damping force adjusting bolt for slow compression damping NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the...

Page 42: ...and thereby harden the compres sion damping turn the adjusting bolt in direction a To decrease the compres sion damping force and thereby soften the compression damping turn the ad justing bolt in direction b 1 Spring preload adjusting ring 2 Position indicator 3 Extension bar 4 Special wrench Spring preload setting Minimum soft 1 Standard 4 Maximum hard 9 1 4 3 2 1 Rebound damping force adjusting...

Page 43: ... 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 absorber assemb...

Page 44: ...model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the inner diameter of the exhaust pipe The EXUP system valve is con stantly adjusted in accordance with the engine speed by a computer controlled servomotor NOTICE ECA15610 The EXUP system has been set and extensively tested at the Yamaha factory Changing the...

Page 45: ...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 EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing ...

Page 46: ... 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 switc...

Page 47: ...ints ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or dam age and check hose connections 4 17 4 19 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 13 Coolant Check coolant level in reservoir If necessa...

Page 48: ...ttle grip free play and lubricate cable and grip housing 7 19 7 30 Control cables Make sure that operation is smooth Lubricate if necessary 7 29 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 27 7 29 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 20 7 23 Brake and shift pedals Make s...

Page 49: ...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 28 ITEM CHECKS PAGE U1JS21E0 book Page 3 Friday August 10 2012 1 26 PM ...

Page 50: ...stop system The engine stops automatically if left idling for 20 minutes In this case the multi function display indicates error code 70 but this is not a mal function Push the start switch to clear the error code and to restart the engine EAU26957 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...

Page 51: ...ife never ac celerate hard when the engine is cold EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NO...

Page 52: ... 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 EAU17083 0 1000 km 0 600 mi Avoid prolonged operation above 8300 r min NOTICE After 1000 km 600 mi of operation the engine oil must be change...

Page 53: ...d 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 U1JS21E0 book Page 4 Friday August 10 2012 1 26 PM ...

Page 54: ...n 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 EWA15460 Brake discs calipers ...

Page 55: ...n 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 U1JS21E0 book Page 2 Friday August 10...

Page 56: ...ance 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 synchroniz...

Page 57: ... fluid leakage Replace brake pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 6 Brake fluid Replace Every 2 years 7 Wheels Check runout and for damage 8 Tires Check tread depth and for dam age Repla...

Page 58: ...ed grease Every 20000 km 12000 mi 13 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Shift pedal pivot shaft Lubricate with lithium soap based grease 18 Sidestand Check...

Page 59: ...ling 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 JOB...

Page 60: ...r 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 U1JS21E0 book Page 7 Friday Au...

Page 61: ...cribed in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU44932 Cowlings A and B To remove a cowling 1 Remove the bolts quick fasteners and quick fastener screw 1 Cowling A 1 Cowling B 2 Cowling C 1 Panel A 2 Panel B 2 1 1 Cowling A 2 Bolt 3 Quick fastener 1 Quick fastener 2 3 1 2 2 2 U1JS21E0 book Page 8 Friday August 10 2012 1 26 PM ...

Page 62: ... the slot slide the cowling forward and then remove the re maining projections from the slots as shown 4 Disconnect the turn signal light lead coupler 1 Quick fastener 2 Quick fastener screw 1 Cowling B 2 Bolt 3 Quick fastener 1 Quick fastener 1 Quick fastener 2 Quick fastener screw 1 Cowling A 2 Cowling B U1JS21E0 book Page 9 Friday August 10 2012 1 26 PM ...

Page 63: ...hown 4 Install the bolts quick fasteners and quick fastener screw EAU39093 Cowling C To remove the cowling 1 Remove cowling B and panel B See page 7 11 2 Unfasten the wire harness by pressing on the projection to open the plastic fastener 1 Cowling A 2 Turn signal light lead coupler 1 Cowling B 2 Turn signal light lead coupler 1 Cowling A 2 Turn signal light lead coupler 1 Cowling B 2 Turn signal ...

Page 64: ...ss in the orig inal position and then close the plastic fastener 4 Install the cowling and the panel EAU39062 Panels A and B To remove a panel Remove the bolts and then pull the panel off as shown To install a panel Place the panel in the original position and then install the bolts 1 Plastic fastener 2 Projection 3 Wire harness 1 Cowling C 2 Bolt 3 Quick fastener 1 Cowling C 2 Slot 3 Front cowlin...

Page 65: ...cessive 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 estimat...

Page 66: ...gain to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark remove the engine oil filler cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the engine oil dipstick and then install and tight en the oil filler cap To change the engine oil with...

Page 67: ...filter wrench is available at a Yamaha dealer 9 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 10 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 1 2 1 Shift arm bolt 2 Shift arm 3 Oil filter cartridge...

Page 68: ...engine oil and then install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In 1 Tor...

Page 69: ...rication chart EAU39087 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TIP The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in ...

Page 70: ...See page 7 8 3 Place a container under the engine to collect the used coolant 4 Remove the radiator cap WARNING Never attempt to re move the radiator cap when the engine is hot EWA10381 5 Remove the coolant drain bolt and its gasket to drain the cooling sys tem 6 Move the hose clamp in the direc tion shown and then disconnect the radiator hose to drain the radi ator 7 Remove the coolant reservoir ...

Page 71: ...and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 17 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 18 Install the cowlings 1 Coolant reservoir cap 2 Coolant rese...

Page 72: ...gine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21384 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 throttle grip free play and if necessary have a Yamaha deal er adjust it Engine idling speed 1250 1350 r min 1 Throttle g...

Page 73: ...A10503 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 ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories appro...

Page 74: ...e 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 TIP The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This motorcycle is equipped with tube less tires tire air valves and cast wheels Tires age even if they have not been used or...

Page 75: ...ollowing points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi ...

Page 76: ...d mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free play turn the clutch lever free play adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b TIP If the specified clutch lever free play cannot be obtained as desc...

Page 77: ... loss of control and an acci dent EAU22273 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking takes ef fect If necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light swit...

Page 78: ... a Yamaha dealer replace the brake pads as a set EAU46291 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out 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 a wear indicator groove almost appears have a Yamaha dealer replace the brake ...

Page 79: ... reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17640 Brake fluid may damage painted sur faces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid lev...

Page 80: ...slack should be checked before each ride and adjusted if necessary EAU22774 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 neu tral position 3 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows ...

Page 81: ...s are in the same position for proper wheel alignment Use the end of the swingarm as the reference point for the alignment marks 3 Tighten the axle nut to the speci fied torque 4 Tighten the adjusting bolts in direc tion a to their specified torque 5 Tighten the locknuts to their speci fied torque 6 Make sure that the drive chain pull ers are in the same position the drive chain slack is correct a...

Page 82: ...ipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11111 EAU23095 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the...

Page 83: ...stalled Even though the cover is installed correctly it does not completely protect the cable from water entry Therefore use care not to pour water directly onto the cover or cable when washing the vehicle If the cable or cover becomes dirty wipe clean with a moist cloth EAU44273 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked befor...

Page 84: ...d should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 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 85: ...eck the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds ...

Page 86: ...ng EAU23291 Checking 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 EAU50210 Battery The battery is located under the rider seat See page 4 20 This model is equipped with a VRLA Val...

Page 87: ...A16521 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 place NOTICE When removing the battery be sure the key is turned to OFF then d...

Page 88: ...re EWA15131 3 Turn the key to ON 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 Main fuse 2 Fuel injection system spare fuse 3 Starter relay cover 4 Fuel injection system fuse 5 Fuse box 1 6 Backup fuse for clock and immobilizer sys tem 7 Electronic throttle valve fuse 8 Spare f...

Page 89: ... 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 ...

Page 90: ...is 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 EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 1 Turn signal light lens 2 Screw 2 1 U1JS21E0 book Page 37 Friday August 10 2012 1 26 PM ...

Page 91: ...nse plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws 1 Turn signal light bulb 1 Screw 2 License plate light unit 1 ...

Page 92: ...tarting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Ra...

Page 93: ...e to re move it and then remove the wheel NOTICE Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut ECA11051 EAU33935 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the axle bolt lower the front wheel so that it is on the ground and then put the sidestand down 4 Install the brake cal...

Page 94: ... of the wheel axle 10 Tighten wheel axle pinch bolt D then pinch bolt C to the specified torque 11 Retighten pinch bolt D to the spec ified torque 12 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bolt 35 Nm 3 5 m kgf 25 ft lbf Tightening torque Axle bolt 91 Nm 9 1 m kgf 66 ft lbf 1 Front wheel axle pi...

Page 95: ...he rear sprocket and then push the wheel forward 6 Remove the drive chain from the rear sprocket TIP If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel NOTICE...

Page 96: ...nut and then lower the rear wheel so that it is on the ground and then put the sidestand down 4 Adjust the drive chain slack See page 7 27 5 Tighten the axle nut to the speci fied torque 6 Tighten the drive chain slack ad justing bolts in direction b to their specified torque 7 Tighten the locknuts to their speci fied torque 1 Wheel axle 1 Retainer 2 Slot Tightening torque Axle nut 110 Nm 11 m kgf...

Page 97: ...quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15141 When checking the fuel system do not smoke and ...

Page 98: ...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 sta...

Page 99: ...ped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for le...

Page 100: ...outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Alway...

Page 101: ... 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 corrosive in combination with water ...

Page 102: ...mediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stone...

Page 103: ...s where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spar...

Page 104: ...the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more th...

Page 105: ... oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 30 L 2 43 US qt 2 02 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 3 L 4 57 US gal 3 81 Imp gal Fuel re...

Page 106: ... kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x 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...

Page 107: ...beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 7 5 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 ...

Page 108: ...on 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 EAU26520 Model label The model label is affixed to the frame under the passenger seat See page 4 20 Record the information on this la bel in the spa...

Page 109: ...rson 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 device or element of design has been removed or rendered inoper ative by any person U1JS21E0 book Page 2 Friday ...

Page 110: ...cap 4 17 Fuses replacing 7 35 H Handlebar switches 4 14 Hazard switch 4 15 Headlight bulb replacing 7 36 Helmet holding cable 4 21 High beam indicator light 4 4 Horn switch 4 14 I Identification numbers 10 1 Ignition circuit cut off system 4 28 Immobilizer system 4 1 Immobilizer system indicator light 4 7 Indicator lights and warning lights 4 4 L Labels location 1 1 License plate light bulb replac...

Page 111: ...oubleshooting 7 44 Troubleshooting charts 7 45 Turn signal indicator lights 4 4 Turn signal light bulb replacing 7 37 Turn signal switch 4 14 V Valve clearance 7 20 Vehicle identification number 10 1 W Wheel bearings checking 7 33 Wheel front 7 40 Wheel rear 7 42 Wheels 7 23 U1JS21E0 book Page 2 Friday August 10 2012 1 26 PM ...

Page 112: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 113: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM ...

Page 114: ...PRINTED IN JAPAN 2012 09 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER ...

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