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PERIODIC MAINTENANCE AND MINOR REPAIR

6-6

• Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master

and release cylinders, and change the brake and clutch fluids.

• Replace the brake and clutch hoses every four years and if cracked or damaged.

U5P520E0.book Page 6 Thursday, March 13, 2008 1:41 PM

ProCarManuals.com

Содержание FJR1300APX

Страница 1: ...5P5 28199 20 FJR1300APX OWNER S MANUAL ProCarManuals com ...

Страница 2: ...U5P520E0 book Page 2 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 3: ...all advantages of your FJR1300APX The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The...

Страница 4: ...maha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The illustrations in this manual show the basic FJR1300AX model and may therefore slightly differ from the FJR1300APX model The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNIN...

Страница 5: ... by Yamaha Motor Co Ltd 1st edition February 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5P520E0 book Page 2 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 6: ...RTANT RIDING POINTS 5 1 Starting the engine 5 1 Shifting 5 2 Tips for reducing fuel consumption 5 3 Engine break in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing panels 6 7 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Final gear oil 6 12 Coolant 6 14 Cleaning the air filt...

Страница 7: ...light bulb or a tail brake light bulb 6 31 Replacing the license plate light bulb 6 32 Auxiliary light bulb 6 32 Troubleshooting 6 33 Troubleshooting charts 6 34 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U5P520E0 book Page 2 Thursday March 13 2008 ...

Страница 8: ... 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 you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motorists ...

Страница 9: ...therwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren ...

Страница 10: ...vel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight 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 th...

Страница 11: ...en are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright If the motorcycle should lean over gasoline may leak out of the ...

Страница 12: ...INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5P520E0 book Page 5 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 13: ...te this vehicle read the owner s manual Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 U5P520E0 book Page 6 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 14: ...1 5 Seat page 3 18 6 Final gear oil filler bolt page 6 12 7 Final gear oil drain bolt page 6 12 8 Shock absorber assembly spring preload adjusting lever page 3 25 9 Air filter element page 6 15 10 Shift pedal page 3 14 11 Engine oil filler cap page 6 9 12 Engine oil filter cartridge page 6 9 13 Engine oil level check window page 6 9 U5P520E0 book Page 1 Thursday March 13 2008 1 41 PM ProCarManuals...

Страница 15: ...eld page 3 11 5 Battery page 6 28 6 Main fuse page 6 29 7 Front fork compression damping force adjusting screw page 3 24 8 Brake pedal page 3 14 9 Shock absorber assembly rebound damping force adjusting knob page 3 25 10 Rear brake fluid reservoir page 6 22 U5P520E0 book Page 2 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 16: ...er page 3 6 6 Speedometer page 3 5 7 Multi function display page 3 6 8 Front brake fluid reservoir page 6 22 9 Right handlebar switches page 3 11 10 Brake lever page 3 14 11 Throttle grip page 6 17 12 Main switch steering lock page 3 2 13 Headlight beam adjusting knob page 3 22 14 Grip warmer adjusting knob page 3 27 U5P520E0 book Page 3 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 17: ...IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep th...

Страница 18: ...ey red bow keep it in a safe place and only use it for code re registering EAU26811 ON All electrical circuits are supplied with power the meter lighting taillights li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF EAU10660 OFF All...

Страница 19: ... switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU39460 Parking The steering is locked and the tail lights license plate light and auxiliary lights are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked ...

Страница 20: ...s warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system See page 3 10 for an explanation of the self diagnosis de vice 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 dea...

Страница 21: ...r check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled This model is also equipped with a self diagnosis device for the immobilizer system See page 3 10 for an expla...

Страница 22: ...o the multi function display The multi function display is equipped with the following an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled on the fuel reserve a clock a fuel meter a coolant temperature meter a transmission gear display an ambient temperature ...

Страница 23: ...1 TRIP 2 F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the SELECT button for at least one second while the display is flash ing If you do not reset the fuel reserve tripmeter manually it will reset itself au tomatically and the display will return to the prior mode after refueling and trav eling 5 km 3 mi Clock To set the clock 1 Push the SELECT button and RESET...

Страница 24: ...oolant temperature meter With the key in the ON position the coolant temperature meter indicates the temperature of the coolant When the key is turned to ON all of the dis play segments of the coolant tempera ture meter will appear one after the other and then disappear in order to test the electrical circuit The coolant temperature varies with changes in the weather and engine load If the top seg...

Страница 25: ...mperature falls be low 9 C a lower temperature than 9 C will not be displayed If the ambient temperature climbs above 50 C a higher temperature than 50 C will not be displayed The accuracy of the temperature reading may be affected when riding slowly approximately under 20 km h or when stopped at traffic signals railroad crossings etc Instantaneous fuel consumption mode The instantaneous fuel cons...

Страница 26: ...f fuel necessary to trav el 100 km is displayed To reset the average fuel consumption display push the RESET button to se lect the mode again and then push the RESET button for 1 second while the display is flashing NOTE To switch between the two aver age fuel consumption displays push the RESET button for 1 second when either display is shown After resetting an average fuel consumption display _ ...

Страница 27: ...rror appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the s...

Страница 28: ...key is turned to OFF the windshield will automatically return to the lowest position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank th...

Страница 29: ...oward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch lever position adjusting dial To adjust the distance between the clutch lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appro...

Страница 30: ...the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU39540 Brake pedal The brake pedal is on the right side of the vehicle This model is equipped with a unified brake system When pressing down on the brake ped al the rear brake and a portion ...

Страница 31: ...under the seat and if the brake lever or brake ped al are even slightly applied a vi bration can be felt at the lever and pedal but these do not indicate a malfunction When the ABS is activated the brakes are operated in the usual way A pulsating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner to experie...

Страница 32: ...ess the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler tube as sh...

Страница 33: ...d reduce maintenance costs EAU13443 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA16490 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasol...

Страница 34: ...at is properly secured before riding The seat height can be adjusted to change the riding position See page 3 18 EAU40970 Adjusting the seat height The seat height can be adjusted to one of two positions to suit the rider s pref erence The seat height was adjusted to the lower position at delivery To change the seat height to the high position 1 Remove the seat See page 3 18 2 Remove the seat heig...

Страница 35: ...down to lock it in place as shown To change the seat height to the low position 1 Remove the seat See page 3 18 2 Remove the seat height position adjuster by pulling it upward 3 Move the seat holder cover to the upper position 4 Install the seat height position ad juster so that the L mark is aligned with the match mark 1 Seat height position adjuster 1 Seat holder cover 1 Seat height position adj...

Страница 36: ...ent is located under the seat See page 3 18 WARNING EWA10961 Do not exceed the load limit of 1 kg 2 lb for the storage com partment Do not exceed the maximum load of 212 kg 467 lb for the ve hicle When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet 1 Seat height position adjuster 2 L mark 3 Match mark 1 ...

Страница 37: ... Turn the key to OFF to preserve the battery To close the accessory box 1 Fold the accessory box lid down 2 Remove the key CAUTION ECA11800 Do not place heat sensitive items in the accessory box The accessory box gets extremely hot especially when the engine is running or is hot WARNING EWA11421 Do not exceed the load limit of 0 3 kg 0 66 lb for the accessory box Do not exceed the maximum load of ...

Страница 38: ...beams turn the knobs in direction a To lower the headlight beams turn the knobs in di rection b EAU39641 Handlebar position The handlebars can be adjusted to one of three positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handlebars EAU39621 Opening and closing the cowl ings The cowlings can be tilted back 30 mm 1 18 in for added ventilation to suit the ridin...

Страница 39: ...ly installed before riding EAU39671 Rear view mirrors The rear view mirrors of this vehicle can be folded forward or backward for park ing in narrow spaces Fold the mirrors back to their original position before riding WARNING EWA14371 Be sure to fold the rear view mirrors back to their original position before riding 1 Quick fastener screw 1 Open position 1 Quick fastener screw 1 Closed position ...

Страница 40: ... appropriate groove on the ad justing mechanism with the top of the front fork cap bolt Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting knob on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob on each fork leg in direc tion b 1 Spring preload adjus...

Страница 41: ...ment 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 EAU40980 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing lever and a rebound damping force adjusting knob CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or...

Страница 42: ...er The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor dampi...

Страница 43: ...orn or damaged stop using the grip warmers and replace the grips WARNING EWA14510 Do not turn the grip warmer knob while the vehicle is moving EAU15301 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignit...

Страница 44: ...tch 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 WARNING EWA10260 The vehicle must be placed on the cent...

Страница 45: ...Does the engine stall After the engine has stalled 10 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 be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Y...

Страница 46: ...rned off and the load must never exceed 30 W 2 5 A otherwise the battery may dis charge To use the auxiliary DC jack 1 Open the accessory box lid See page 3 21 2 Turn the key to OFF 3 Remove the auxiliary DC jack cap 4 Insert the accessory plug into the auxiliary DC jack 5 Turn the key to ON and then start the engine See page 5 1 WARNING EWA14360 To prevent electrical shock or short circuiting mak...

Страница 47: ...herefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not working pr...

Страница 48: ...raulic 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 6 21 6 22 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 in reservoir If necessary add recommended brake flu...

Страница 49: ...mooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches ...

Страница 50: ... a turnover To start the engine after a turnover be sure to turn the main switch to OFF and then to ON Fail ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAU40231 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 p...

Страница 51: ...conds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting...

Страница 52: ...gine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings 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 foll...

Страница 53: ...g the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 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 Do not park on a slope or on soft ground otherwise the vehicle may overturn CAU...

Страница 54: ... familiar with mainte nance work have a Yamaha dealer do it for you EAU17380 Owner s tool kit The owner s tool kit is located under the seat See page 3 18 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be nec...

Страница 55: ...ols data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Air filter element Clean Replace 5 Clutch Check opera...

Страница 56: ...amage 12 Swingarm Check operation and for exces sive play Lubricate with lithium soap based grease Every 50000 km 30000 mi 13 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Brake lever pivot shaft Lubricate with silicone grease NO...

Страница 57: ...ck ab sorber for oil leakage 23 Rear suspension re lay arm and con necting arm pivoting points Check operation Lubricate with lithium soap based grease 24 Fuel injection Adjust engine idling speed and synchronization 25 Engine oil Change Check oil level and vehicle for oil leakage 26 Engine oil filter car tridge Replace 27 Cooling system Check coolant level and vehicle for coolant leakage Change E...

Страница 58: ...e grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 32 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary 33 Muffler and exhaust pipe Check the screw clamp s for looseness 34 Lights signals and switches Check operation Adjust headli...

Страница 59: ...mponents of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged U5P520E0 book Page 6 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 60: ...e the panel Remove the bolts and the quick fasten er and then take the panel off To install the panel Place the panel in the original position and then install the bolts and the quick fastener EAU45720 Panels B and C To remove one of the panels 1 Remove the seat See page 3 18 2 Remove the bolts and the quick fastener screws and then take the panel off 1 Panel A 1 Panel B 1 Panel C 1 Panel A 2 Bolt...

Страница 61: ...lugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such ...

Страница 62: ...e each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm...

Страница 63: ...under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 6 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1 En...

Страница 64: ...In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening tor...

Страница 65: ...gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle In addi tion the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrica tion chart WARNING EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel T...

Страница 66: ...e final gear case 4 Install the final gear oil drain bolt and then tighten it to the specified torque 5 Refill with the recommended final gear oil to the brim of the filler hole 6 Install the oil filler bolt and then tighten it to the specified torque 7 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Final gear oil filler bolt 2 Final gear oil drain bolt 3 Correct...

Страница 67: ...olant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove the coolant reservoir cap 4 Add coolant or distilled water to raise the coolant to the maximum level mark install the coolant res ervoir cap CAUTIO...

Страница 68: ...coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant EAU20471 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean...

Страница 69: ... seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 7 Install the air filter case cover by in stalling the screws CAUTION ECA15410 Make sure that the fuel tank breath er overflow hose is not pinched 8 Install the intake air shroud by in stalling the screw and the quick fas...

Страница 70: ...le free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle 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...

Страница 71: ...NEVER OVERLOAD THE VEHI CLE Operation of an overload ed vehicle may result in tire damage loss of control or se vere injury Make sure that the total weight of rider cargo and accessories does not exceed the specified maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the vehicle and distribute t...

Страница 72: ... edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure t...

Страница 73: ...ehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place 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 u...

Страница 74: ... which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary have a Yamaha dealer ad just the brake light switch EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU43431 Front brake pads The ...

Страница 75: ...ficient brake fluid may allow air to enter the brake or clutch systems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage N...

Страница 76: ...y lower the boiling point of the fluid and may result in vapor lock and dirt may clog the ABS hy draulic unit valves 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 have a Yamaha dealer check the cause EA...

Страница 77: ...ll cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions 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 ped...

Страница 78: ...e lever Clutch lever 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 lubricant Silicone grease U5P520E0 book Page 25 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 79: ...ler check or re pair it EAUM1650 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart EAU23250 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap...

Страница 80: ... times to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU45510 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and ...

Страница 81: ... the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with...

Страница 82: ...ads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha deale...

Страница 83: ...have a Yamaha dealer check the electrical system 1 Fuse box 2 Right radiator fan fuse 3 Left radiator fan fuse 4 Hazard fuse 5 Backup fuse for odometer clock and immo bilizer system 6 ABS solenoid fuse 7 Fuel injection system fuse 8 Headlight fuse 9 Signaling system fuse 10 ABS control unit fuse 11 Ignition fuse 12 Auxiliary DC jack fuse 13 Spare fuse Specified fuses Main fuse 50 0 A Headlight fus...

Страница 84: ...40990 Replacing a rear turn signal light bulb or a tail brake light bulb 1 Remove the socket together with the defective bulb by turning it counterclockwise 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the socket together with the bulb by turning it clockwise 1 Turn ...

Страница 85: ...ull 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 EAU39020 Auxiliary light bulb If the auxiliary light does not come on have a Yamaha dealer check the elec trical circuit or replace the bulb 1 Screw 2 License plate light unit 1 License plate light bulb U5P520E0 book Page 32...

Страница 86: ...ooting 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 are often inferi or have ...

Страница 87: ... no compression Check the ignition Have a Yamaha 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 Bat...

Страница 88: ...down on the cap while turning it counterclockwise and then remove the cap NOTE 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 leakage Hav...

Страница 89: ...ts with plas tic bags 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 and wheel axles Always rinse the dirt and de greaser...

Страница 90: ...vered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the...

Страница 91: ...d using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26241 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow...

Страница 92: ...he spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becomin...

Страница 93: ...mp qt Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 20 L 0 21 US qt 0 18 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 60 L 2 75 US qt 2 29 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 25 0 L 6 61 US ...

Страница 94: ...b Front 270 kPa 2 70 kgf cm 39 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 270 kPa 2 70 kgf cm 39 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 Rig...

Страница 95: ...ht LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS control unit fuse 10 0 A ABS m...

Страница 96: ...n 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 NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle...

Страница 97: ...s are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or element of des...

Страница 98: ... H Handlebar position adjusting 3 22 Handlebar switches 3 11 Hazard switch 3 13 Headlight beams adjusting 3 22 Headlight bulb 6 31 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 28 Immobilizer system 3 1 Immobilizer system indicator light 3 5 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 Lice...

Страница 99: ...6 18 Tool kit 6 1 Troubleshooting 6 33 Troubleshooting charts 6 34 Turn signal indicator lights 3 4 Turn signal light or tail brake light bulb replacing 6 31 Turn signal switch 3 12 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheels 6 20 Windshield position adjusting switch 3 12 U5P520E0 book Page 2 Thursday March 13 2008 1 41 PM ProCarManuals com ...

Страница 100: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Страница 101: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Страница 102: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2008 03 0 3 1 CR E ProCarManuals com ...

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