Yamaha YZFR6A Owner'S Manual Download Page 76 | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-24

7

EAU21962

Cast wheels

To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

●

The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed 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.

EAU33891

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. 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 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 direction
(b).

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

U1JS10E0.book Page 24 Monday, August 9, 2010 10:47 AM

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Summary of Contents for YZFR6A

Page 1: ...DIC183 1JS 28199 10 YZFR6A C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 24 55 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1JS10E0 book Page 1 Monday August 9 2010 10 47 AM ...

Page 3: ...ntain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancie...

Page 4: ...ey 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 NOTICE TIP U1JS10E0 book Page 1 M...

Page 5: ...Motor Corporation U S A 1st edition August 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 24 55 U1JS10E0 book Page 2 Monday August 9 2010 10 47 AM ...

Page 6: ...T 7 1 Owner s tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 5 Removing and installing cowlings and panels 7 9 Checking the spark plugs 7 13 Canister for California only 7 14 Engine oil and oil filter cartridge 7 14 Coolant 7 17 Air filter element 7 20 Checking the engine idling speed 7 20 Checking the throttle grip free play...

Page 7: ...otorcycle 7 40 Front wheel 7 40 Rear wheel 7 42 Troubleshooting 7 44 Troubleshooting charts 7 46 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 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITE...

Page 8: ...cle 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 5 6 4 U1JS10E0 book Page 1 Monday August 9 2010 10 47 AM ...

Page 9: ...protective clothing PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 TIRE INFORMATION Cold tire 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 WARNING Improper loading can cause loss of control Read owner ...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 1 2 3 U1JS10E0 book Page 3 Monday August 9 2010 10 47 AM ...

Page 11: ...2 1 3 1 4 1 HOWTO LAYOUT FUEL HOSES 13S 2178A 10 EMISSION HOSE ROUTING 13S 21686 10 4 3 2 1 FUEL TANK THROTTLE BODY CHARCOAL CANISTER ATMOSPHERE VACUUM HOSE ROUTING 13S 21684 10 INTAKE MANIFOLD PRESS SENSOR 1 2 3 4 2 California only 1 California only 3 California only U1JS10E0 book Page 4 Monday August 9 2010 10 47 AM ...

Page 12: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ...

Page 13: ...d contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that covers your legs ankles and feet The eng...

Page 14: ... of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any...

Page 15: ...r front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain access...

Page 16: ...ie 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 for example to rubber mounted handlebars or turn signals or parts that could break Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs...

Page 17: ...6 Shock absorber assembly compression damping force adjusting bolt for slow compression damping page 4 21 7 Owner s tool kit page 7 2 8 Shock absorber assembly rebound damping force adjusting screw page 4 21 9 Shift pedal page 4 12 10 Engine oil filter cartridge page 7 14 11 Engine oil drain bolt page 7 14 12 Front fork compression damping force adjusting bolt for fast compres sion damping page 4 ...

Page 18: ... injection system fuse page 7 36 6 Battery page 7 34 7 Air filter element page 7 20 8 Coolant reservoir page 7 17 9 Radiator cap page 7 17 10 Engine oil filler cap page 7 14 11 Coolant drain bolt page 7 18 12 Engine oil dipstick page 7 14 13 Brake pedal page 4 13 14 Rear brake light switch page 7 26 15 Rear brake fluid reservoir page 7 27 U1JS10E0 book Page 2 Monday August 9 2010 10 47 AM ...

Page 19: ... 12 2 Left handlebar switches page 4 11 3 Main switch steering lock page 4 1 4 Multi function meter unit page 4 5 5 Front brake fluid reservoir page 7 27 6 Right handlebar switches page 4 11 7 Brake lever page 4 12 8 Throttle grip page 7 21 U1JS10E0 book Page 3 Monday August 9 2010 10 47 AM ...

Page 20: ...gine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 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 EAU10683 LOCK The steering is locked and all electrical systems...

Page 21: ...rical 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 TIP Even if the oil level is sufficient the warning light may flicker when riding on a slope or ...

Page 22: ...nosis device for the fuel level de tection circuit If a problem is detected in the fuel level detection circuit the fol lowing cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times and then go off for 3 0 seconds If this oc curs have a Yamaha dealer check the vehicle EAU11428 Coolant temperature warning light This warning light comes on if th...

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 F TRIPA F TRIPA F TRIPA F U1JS10E0 book Page 4 Monday August...

Page 24: ...ift to the next higher gear The electrical circuit of the indicator light can be checked by turning the key to ON The indicator light should 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 9 for a detailed ex planation of the fun...

Page 25: ...speedometer and odometer tripmeter displays be tween kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal cir...

Page 26: ...it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change the display to the stopwatch mode select it by pushing the SE LECT button The stopwatch digits will start flashing Release the SE LECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push th...

Page 27: ...e warning light comes on if the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air in take temperature is displayed Self diagnosis device This model is equipped with a self ...

Page 28: ...the engine speed at which the indi cator light will be deactivated Shift timing indicator light bright ness This function allows you to adjust the brightness of the indicator light to suit your preference TIP In this mode the right display shows the current setting for each function except the shift timing indicator light activity function To adjust the brightness of the multi function meter displ...

Page 29: ...sh the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light deactiva tion function To set the shift timing indicator light de activation function TIP The shift timing indicator light de activation function can be set 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 ...

Page 30: ... 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 EAU41700 The engine ...

Page 31: ...nation with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU33851 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a brake lever position adjusting knob To adjust the distance between the brake lever and the handleb...

Page 32: ...o open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover 1 Brake pedal 1...

Page 33: ...ition 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 immedi ately N...

Page 34: ...ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU48760 Fuel tank breather overflow hose TIP For California See page 7 14 for breather hose information Before operating the motorcycle Ch...

Page 35: ...aust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU39032 Seats Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the bo...

Page 36: ... 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 seats are properly secured before riding 1 Projection 2 Seat holder 1 Passenger seat lock 2 Unlock 1 Projection 2 Seat holder U1JS10E0 book Page 17 Monday...

Page 37: ...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 38: ...pres 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 decre...

Page 39: ...on 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 1 a b Rebound damping setting Minim...

Page 40: ...sion 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 spring preload...

Page 41: ...nd 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 42: ...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 assembl...

Page 43: ...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 44: ...tem 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 functio...

Page 45: ... 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 46: ...ng 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 4 14 4 15 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 14 Coolant Check coolant level in reservoir If necessary add...

Page 47: ...ottle grip free play and lubricate cable and grip housing 7 21 7 31 Control cables Make sure that operation is smooth Lubricate if necessary 7 30 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 28 7 30 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 21 7 24 Brake and shift pedals Make ...

Page 48: ...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 25 ITEM CHECKS PAGE U1JS10E0 book Page 3 Monday August 9 2010 10 47 AM ...

Page 49: ... 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 EAU16257 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 ...

Page 50: ...he 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 ECA10260 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 transmissio...

Page 51: ...recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various...

Page 52: ...eat may cause discoloration of the exhaust pipe but this is normal EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn inc...

Page 53: ...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 1 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers ...

Page 54: ...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 U1JS10E0 book Page 2 Monday August 9 ...

Page 55: ... 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 4 Crank...

Page 56: ...tion sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months U1JS10E0 book Page 4 Monday August 9 2010 10 47 AM ...

Page 57: ...eck operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam age Replace ...

Page 58: ...repack with lithium soap based grease Every 12000 mi 19000 km 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease ligh...

Page 59: ...il Change warm engine before draining 23 Engine oil filter car tridge Replace 24 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or engine oil thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 100...

Page 60: ...l the reservoirs as required 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 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 28 Lights signals and switches Check operation Adjust headlight be...

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 U1JS10E0 book Page 9 Monday August 9 2010 10 47 AM ...

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 U1JS10E0 book Page 10 Monday August 9 2010 10 47 AM ...

Page 63: ...shown 4 Install the bolts quick fasteners and quick fastener screw EAU39092 Cowling C To remove the cowling 1 Remove cowling B and panel B See page 7 9 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: ...ntenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles 4 Remove the engine oil dipstick and wipe it clean insert it back into the hole without scre...

Page 67: ... the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 6 12 if the oil filter cartridge is not being replaced 6 Remove the shift arm bolt and then pull the shift arm off the shift shaft 7 Remove the fuel tank breath er overflow hoses from the guides 8 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 2 ...

Page 68: ...arm with the match mark on the shift shaft and installing the shift arm bolt then tightening it to the specified torque NOTICE Be sure to align the match marks to ensure proper shifting If the match marks are not aligned the shift arm will not move correctly and you may not be able to shift up or down ECA15342 13 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the...

Page 69: ...t flickers or remains on even if the oil level is correct immediately turn the engine off and have a Yamaha dealer check the vehicle 16 Turn the engine off and then check the oil level and correct it if necessary 17 Install the cowling EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenanc...

Page 70: ... against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Install the panel EAU39004 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove cowlings B and C See page 7 9 3 Place a ...

Page 71: ...tall the coolant reservoir cap 14 Pour the recommended coolant into the radiator until it is full 15 Install the radiator cap start the engine let it idle for several min utes 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 1 Coolant drain bolt ...

Page 72: ...36764 Air filter element The air filter element must be replaced at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the air filter element EAU44734 Checking the engine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer Engine idling speed 1250 1350 r min U1JS10E0 book Page 20 Monday August 9 2010 1...

Page 73: ...tion chart EAU21754 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10503 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire ai...

Page 74: ...ke related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience to do so Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 ...

Page 75: ... Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 10...

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

Page 77: ...m WARNING EWA14211 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of control and an acci dent 1 No brake lever free play 1 U1JS10E0 book Page 25 M...

Page 78: ...EAU36890 Front brake pads Each front brake pad is provided with wear indicators which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a s...

Page 79: ...e recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid an...

Page 80: ...be checked before each ride and adjusted if necessary EAU22773 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 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure...

Page 81: ...t marks on each drive chain puller make sure that both chain pullers 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 1 Drive chain slack adjusting bolt...

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 EAU44272 Checking and lubricating the brake and shift pedals Brake pedal Shift pedal The operation of the brake and shift pedals...

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: ...ering 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 16 This model is equipped with a VRLA ...

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: ...ire 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 Fuel injection system fuse 4 Fuse box 1 5 Backup fuse for clock 6 Electronic throttle valve fuse 7 Spare fuse 1 Fuse box 2 2 Left radiator fan fuse 3 R...

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 U1JS10E0 book Page 38 Monday August 9 2010 10 47 AM ...

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: ... 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 Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU34595 To remove th...

Page 93: ... 4 Install the brake calipers by install ing the bolts and then tightening them to the specified torque TIP Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders and reflectors by installing the bolts and nuts 6 Tighten the axle bolt to the speci fied torque TIP While tightening the axle bolt hold the...

Page 94: ...AU25080 Rear wheel EAU44953 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Loosen the axle nut 2 Lift the rear wheel off the ground according to the procedure on page 7 40 3 Remove the axle nut 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 bo...

Page 95: ...not be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel NOTICE Do not apply the brake after the wheel has been re moved together with the brake disc otherwise the brake pads will be forced shut ECA11071 EAU39173 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side...

Page 96: ...er The following troubleshooting charts represent quick and easy procedures 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...

Page 97: ...RIODIC MAINTENANCE AND ADJUSTMENT 7 45 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U1JS10E0 book Page 45 Monday August 9 2010 10 47 AM ...

Page 98: ...er check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly The engine turns o...

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

Page 102: ...any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA11131 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 ac eton...

Page 103: ... spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing 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 EWA10951 e Remove the spark ...

Page 104: ...MOTORCYCLE CARE AND STORAGE 8 5 8 TIP Make any necessary repairs before storing the motorcycle U1JS10E0 book Page 5 Monday August 9 2010 10 47 AM ...

Page 105: ... 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 reserve amoun...

Page 106: ...t 250 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 Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foo...

Page 107: ... indicator light LED High 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 Shift timing indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 15 0 A 2 Fuel injection system fuse 15 0 A ...

Page 108: ...entification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 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 ...

Page 109: ...en ordering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 Vehicle Emission Control Information label 1 U1JS10E0 book Page 2 Mon...

Page 110: ... and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seve...

Page 111: ...icle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc E...

Page 112: ...inder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km ...

Page 113: ...RMATION 10 6 10 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U1JS10E0 book Page 6 Monday August 9 2010 10 47 AM ...

Page 114: ...r warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha ...

Page 115: ...y later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires war...

Page 116: ...ed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing...

Page 117: ...ked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U1JS10E0 book Page 10 Monday August 9 2010 10 47 AM ...

Page 118: ...Handlebar switches 4 11 Headlight bulb replacing 7 37 Helmet holding cable 4 18 High beam indicator light 4 2 Horn switch 4 11 I Identification numbers 10 1 Ignition circuit cut off system 4 25 Indicator lights and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 39 Luggage strap holders 4 24 M Main switch steering lock 4 1 Maintenance ...

Page 119: ...s 4 2 Turn signal light bulb replacing 7 38 Turn signal switch 4 11 V Valve clearance 7 21 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 34 Wheel front 7 40 Wheel rear 7 42 Wheels 7 24 U1JS10E0 book Page 2 Monday August 9 2010 10 47 AM ...

Page 120: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 121: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 122: ...PRINTED IN JAPAN 2010 08 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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