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PERIODIC MAINTENANCE AND ADJUSTMENT

7-25

7

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).

4. Tighten the locknut.

EAU22271

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).

1. Locknut

2. Clutch lever free play adjusting nut (crank-

case)

1. Rear brake light switch

2. Rear brake light switch adjusting nut

U13S11E0.book Page 25 Wednesday, June 11, 2008 6:10 PM

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Summary of Contents for YZFR6Y

Page 1: ...DIC183 13S 28199 11 YZFR6Y C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 22 51 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U13S11E0 book Page 1 Wednesday June 11 2008 6 10 PM ...

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 U13S11E0 book Page 1 W...

Page 5: ... Motor Corporation U S A 1st edition May 2008 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 22 51 U13S11E0 book Page 2 Wednesday June 11 2008 6 10 PM ...

Page 6: ...ontrol system 7 3 General maintenance and lubrication chart 7 4 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 18 Air filter element 7 20 Checking the engine idling speed 7 21 Checking the throttle cable free play 7 21 Valve clearance 7 21 Tires 7 22 Cast wheels 7 24 Adjusting the cl...

Page 7: ...7 43 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 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED SERVICE Y E S 10 9 U13S11E0 book...

Page 8: ...They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 4 5 6 7 8 9 U13S11E0 book Page 1 Wednesday June 11 2008 6 10 PM ...

Page 9: ...YOUT FUEL HOSES 1 2 2 2 3 2 4 2 2 1 3 1 4 1 1 1 FUEL DELIVERY FUEL PUMP FUEL FILTER PRESS REGULATOR 13S 2178A 00 FUEL TANK 1 4B5 2815K 00 Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent NOTICE U13S11E0 book Page 2 Wednesday June 11 2008 6 10 PM ...

Page 10: ...28446 A1 3 kg 7 lbs 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 WARNING 4C8 2118K 00 BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protectibe clothing PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 U13S11E0 book Page 3 Wednesday June 11 2008 6 10 PM ...

Page 11: ...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 12: ... 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 engi...

Page 13: ...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 14: ...ght distribution or aerody namic changes If accessories are added to the handlebar or 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 ...

Page 15: ... 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 1...

Page 16: ... page 7 34 7 Air filter element page 7 20 8 Front brake fluid reservoir page 7 26 9 Radiator cap page 7 18 10 Coolant reservoir page 7 18 11 Engine oil filler cap page 7 14 12 Coolant drain bolt page 7 19 13 Engine oil dipstick page 7 14 14 Brake pedal page 4 13 15 Rear brake light switch page 7 25 16 Rear brake fluid reservoir page 7 26 U13S11E0 book Page 2 Wednesday June 11 2008 6 10 PM ...

Page 17: ...ever page 4 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 Right handlebar switches page 4 11 6 Brake lever page 4 12 7 Throttle grip page 7 21 U13S11E0 book Page 3 Wednesday June 11 2008 6 10 PM ...

Page 18: ...ngine 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 EAU10681 LOCK The steering is locked and all electrical system...

Page 19: ...ht comes on if the en gine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit TIP Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is no...

Page 20: ...agnosis 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 EAU11425 Coolant temperature warning light This warning light comes on if ...

Page 21: ...riding 117 134 C 243 274 F Temperature display 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 45 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 45 TRIPA F TRIPA F TRIPA F TRIPA F U13S11E0 book Page 4 Wednesda...

Page 22: ...e to shift to the next higher gear The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit See page 4 9 for a detailed expla nation of the function of this indicator light and on how to set it EAU39254 Multi function meter unit WARNING EWA12422 Be s...

Page 23: ...ing indicator light control mode To switch the 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 ...

Page 24: ...t 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 the...

Page 25: ... is set to be displayed the coolant temperature 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 diagno...

Page 26: ...t 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 dis...

Page 27: ...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 28: ...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 t...

Page 29: ...bination 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 handl...

Page 30: ...To 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 ...

Page 31: ...f ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi at...

Page 32: ...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 EAU13444 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10861 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle ne...

Page 33: ... rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original po sition and then install the bolts Passenger seat To remove the passenger seat 1 Insert the key into the passenger seat lock and then turn it clock wise 1 Bolt 1 Projection 2 Seat holder U13S11...

Page 34: ...ats are properly secured before riding EAU39073 Helmet holding cable A helmet holding cable is provided in the owner s tool kit to secure two hel mets to the helmet cable holder equipped on the bottom of the passen ger seat To secure a helmet with the helmet holding cable 1 Remove the passenger seat See page 4 16 2 Clip the middle snap hook of the cable onto the cable holder 1 Passenger seat lock ...

Page 35: ...n remove the cable from the helmet strap buck le 3 Install the passenger seat EAU38943 Adjusting the front fork WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws compres sion damping force adjusting bolts for fast compression damping ...

Page 36: ...rce and thereby harden the rebound damp ing turn the adjusting screw on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in di rection b 1 Spring preload adjusting bolt 1 Current setting 2 Front fork collar Spring preload setting Minimum soft 0 Standard 2 Maximum hard 5 1 Rebound damping force adjust...

Page 37: ...cks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary 1 Compression damping fo...

Page 38: ...ction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn ...

Page 39: ...e to small differences in production WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Rebound damping setting Minimum soft 20 click s in direction b Standard 16 click s in direction b Maximum hard 3 click s in ...

Page 40: ...er as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU38961 Luggage strap holders There are six luggage strap holders four on the bottom of the passenger seat and one on each passenger foot rest To use the luggage strap holders on the passenger seat remove the passenger seat unhook the straps from the hooks and then install the seat with the straps hanging ou...

Page 41: ...nd or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not s...

Page 42: ...ission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure U...

Page 43: ...0 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch swit...

Page 44: ...d in the Owner s Manual WARNING EWA11151 Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer Before using this vehicle check the following points U13S11E0 book Page 1 ...

Page 45: ...ion If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 7 26 7 26 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level i...

Page 46: ...cessary 7 22 7 24 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tigh...

Page 47: ... prevent the engine from starting even though the engine will crank when pushing the start switch EAU16254 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sid estand up See page 4 25 for more informa tion 1 ...

Page 48: ...r 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 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 th...

Page 49: ...ded 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 parts i...

Page 50: ...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 51: ...nning 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 EAU17302 Emission controls not only function to ensure cleaner air but are also vital to prope...

Page 52: ... 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 U13S11E0 book Page 2 Wednesday June 11...

Page 53: ...essary 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 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization 6 Exhaust system Check for leakage Tighten if necessary R...

Page 54: ...ck 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 i...

Page 55: ...h 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 lightly No ITE...

Page 56: ...l 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 1000...

Page 57: ... disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the...

Page 58: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 8 7 Replace the brake hoses every four years and if cracked or damaged U13S11E0 book Page 8 Wednesday June 11 2008 6 10 PM ...

Page 59: ... in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU44931 Cowlings A and B To remove one of the cowlings 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 U13S11E0 book Page 9 Wednesday June 11 2008 6 10 PM ...

Page 60: ... 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 screw 2 Quick fastener 1 Cowling B 2 Bolt 3 Quick fastener 1 Quick fastener 1 Quick fastener screw 2 Quick fastener 1 Cowling A 2 Cowling B U13S11E0 book Page 10 Wednesday June 11 2008 6 10 PM ...

Page 61: ...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 62: ...the orig inal position and then close the plastic fastener 4 Install the cowling and the panel EAU39060 Panels A and B To remove one of the panels Remove the bolts and then pull the panel off as shown To install the 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 ...

Page 63: ...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 64: ...eriodic maintenance 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 w...

Page 65: ...il 5 Remove the engine oil filler cap and drain bolt 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 by removing the bolt and pulling it 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 filler cap 1 Engine oil d...

Page 66: ...match mark on the shift arm with the match mark on the shift shaft and installing the bolt then tighten ing 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 then tighten it to the specified...

Page 67: ...t idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause TIP After the engine is started the engine oil level warning light should go off if the oil level is sufficient NOTICE ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 16 Turn...

Page 68: ...e 7 9 4 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15161 NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has bee...

Page 69: ...n the radi ator 7 Remove the coolant reservoir by removing the bolts 8 Remove the coolant reservoir cap and then turn the coolant reservoir upside down to empty it 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant reservoir by in stalling the bolts 11 Connect the radiator hose and then move the hose clamp back to its original...

Page 70: ...icle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 18 Install the cowlings EAU36762 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 Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Antifreeze water mixtu...

Page 71: ...grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Engine idling...

Page 72: ...odel WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Tire air pressure m...

Page 73: ...nly the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires...

Page 74: ...heel 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 Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU33891 Adjusting the clutch lever free play The clutch lev...

Page 75: ...AU22271 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the a...

Page 76: ...e 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 set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU22580 Checking the brake...

Page 77: ...water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly ha...

Page 78: ...EAU39054 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting bolt on each side of the swingarm in direc tion a To loosen the drive chain turn the adjusting bolt on each side of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will over...

Page 79: ...ing in dusty or wet areas Service the drive chain as follows NOTICE ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3...

Page 80: ...ith cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals T...

Page 81: ...er The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U13S11E0 book Page 31 Wednesday June 11 2008 6 10 PM ...

Page 82: ...c maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check 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...

Page 83: ...f the ground See page 7 39 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be che...

Page 84: ...fficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regu...

Page 85: ...6 Fuse box 2 is located under panel A See page 7 9 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 ...

Page 86: ...nosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do 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 ...

Page 87: ...Connect the headlight coupler 6 Install the headlight bulb cover by turning it clockwise 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24181 Tail brake light This model is equipped with an LED type tail brake light If the tail brake light does not come on have a Yamaha dealer check it 1 Headlight coupler 1 Headlight bulb holder U13S11E0 book Page 37 Wednesday June 11 2008 6 10 P...

Page 88: ... then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAU24312 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 1 Screw 1 Turn signal light bulb 1 Screw 1 License plate light bulb 2 Li...

Page 89: ... a stable and level position before starting 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 motorcyc...

Page 90: ...m the left side 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 EAU34532 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the axle bolt and then lower the front wheel so that it is on the ground 4 Install the brake calipers by install ing th...

Page 91: ...nd 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 ...

Page 92: ...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 Do not apply the brake after the wheel has been re moved together with the brake disc otherwise the brake pads will be ...

Page 93: ...ting and loss of power 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 Y...

Page 94: ...IODIC MAINTENANCE AND ADJUSTMENT 7 44 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U13S11E0 book Page 44 Wednesday June 11 2008 6 10 PM ...

Page 95: ...amaha dealer 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 engi...

Page 96: ...ed press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended 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 lea...

Page 97: ...e cleaning 1 Cover the muffler 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 dr...

Page 98: ...tergent 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 corrosive in...

Page 99: ... 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 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 necessar...

Page 100: ...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 plug caps from the spark plugs and then install the spark plugs and the s...

Page 101: ... 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 amount 3 5 L 0 92 US gal 0 77 Imp gal Fuel...

Page 102: ...si 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 foot operation Recommended fl...

Page 103: ...ht 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 Backup fuse 7 ...

Page 104: ...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 105: ...is affixed to the frame under the passenger seat See page 4 16 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer 1 Model label U13S11E0 book Page 2 Wednesday June 11 2008 6 10 PM ...

Page 106: ...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 Seven...

Page 107: ...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 108: ...nder 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 o...

Page 109: ...MATION 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 U13S11E0 book Page 6 Wednesday June 11 2008 6 10 PM ...

Page 110: ...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 111: ...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 112: ...d 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 113: ...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 U13S11E0 book Page 10 Wednesday June 11 2008 6 10 PM ...

Page 114: ...ight 4 2 Horn switch 4 11 I Identification numbers 10 1 Ignition circuit cut off system 4 25 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 38 Luggage strap holders 4 23 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color cau...

Page 115: ...urn signal light bulb replacing 7 38 Turn signal switch 4 11 V Valve clearance 7 21 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 33 Wheel front 7 40 Wheel rear 7 42 Wheels 7 24 U13S11E0 book Page 2 Wednesday June 11 2008 6 10 PM ...

Page 116: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 117: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 118: ...PRINTED IN JAPAN 2008 06 5 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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