OWNER’S MANUAL FJR13AV(C) LIT-11626-19-83 3P6-28199-10
U3P610E0.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FJR13AV(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM IMPORTANT MANUAL INFORMATION EAU10131 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. *Product and specifications are subject to change without notice.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FJR13AV(C) OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, December 2005 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.
U3P610E0.book Page 1 Thursday, January 12, 2006 1:31 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................
U3P610E0.book Page 2 Thursday, January 12, 2006 1:31 PM TABLE OF CONTENTS Lubricating the rear suspension ...6-30 Checking the front fork .................6-30 Checking the steering ...................6-31 Checking the wheel bearings .......6-31 Battery ..........................................6-32 Replacing the fuses ......................6-33 Replacing a headlight bulb ...........6-34 Front turn signal light ....................6-36 Replacing a rear turn signal light bulb or a tail/brake light bulb ....
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION EAU10281 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION 1 ● ● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 211 kg (465 lb) (CAL) 212 kg (467 lb) (U49) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
U3P610E0.book Page 4 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION 1 ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U3P610E0.book Page 5 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U3P610E0.
U3P610E0.book Page 7 Thursday, December 22, 2005 11:16 AM SAFETY INFORMATION 1 6 9 7 10 8 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 270 kPa, {2.70 kgf/cm 2 }, 39psi 290 kPa, {2.90 kgf/cm 2 }, 42psi 270 kPa, {2.70 kgf/cm 2 }, 39psi 290 kPa, {2.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shock absorber assembly spring preload adjusting lever (page 3-23) 10.Air filter element (page 6-18) 11.Shift pedal (page 3-11) 12.Engine oil filler cap (page 6-13) 13.Engine oil filter cartridge (page 6-13) 14.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shock absorber assembly rebound damping force adjusting knob (page 3-23) 10.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Right handlebar switches (page 3-8) 10.Brake lever (page 3-11) 11.Throttle grip (page 6-20) 12.Main switch/steering lock (page 3-1) 13.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10690 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 3 1. Push. 2.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights EAU11060 EAU11530 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS cy braking. If the warning light comes on or flashes while riding, have a Yamaha dealer check the brake system as soon as possible. EAU11601 Speedometer EAU11872 Tachometer The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on or remains on, have a Yamaha dealer check the electrical circuit. 3 1. Tachometer 2. Speedometer 3.
U3P610E0.book Page 4 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU40290 Multi-function display ● ● ● ● ● ● 3 ● ● 1. Multi-function display 2. “SELECT” button 3.
U3P610E0.book Page 5 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS distance traveled from that point. In that case, pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “SELECT” button for at least one second.
U3P610E0.book Page 6 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS 3 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 display segments of the coolant temperature 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.
U3P610E0.book Page 7 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS Ambient temperature mode 20 km/h (12.5 mi/h)] or when stopped at traffic signals, railroad crossings, etc. Average fuel consumption mode Instantaneous fuel consumption mode 3 1. Ambient temperature 1. Average fuel consumption This display shows the ambient temperature from 16 °F to 122 °F in 1 °F increments. The temperature displayed may vary from the ambient temperature.
U3P610E0.book Page 8 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS ● After resetting the average fuel consumption display, “_ _” will be shown for that display until the vehicle has traveled 1 km (0.6 mi). If the multi-function display indicates such an error code, note the code number, and then have a Yamaha dealer check the vehicle. EAU12344 Handlebar switches Left ECA11790 ECA15471 CAUTION: 3 If there is a malfunction, “– –” will be displayed.
U3P610E0.book Page 9 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS Right EAU12493 EAU12660 Windshield position adjusting switch “ ” To move the windshield up, push this switch in direction (a). To move the windshield down, push the switch in direction (b). Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
U3P610E0.book Page 10 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS ECA10061 CAUTION: EAU12830 Clutch lever Do not use the hazard lights for an extended length of time with the engine not running, otherwise the battery may discharge. 3 1. 2. 3. 4. Clutch lever Arrow mark Clutch lever position adjusting dial Distance between clutch lever and handlebar grip The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip.
U3P610E0.book Page 11 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU26822 Brake lever EAU39540 Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Shift pedal 1.
U3P610E0.book Page 12 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39530 ABS 3 The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. The ABS is monitored by an ECU (Electronic Control Unit), which will have recourse to manual braking if a malfunction occurs.
U3P610E0.book Page 13 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13220 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA11090 WARNING EAU13300 Make sure that the fuel tank cap is properly closed before riding. 1.
U3P610E0.book Page 14 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS 3 knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%.
U3P610E0.book Page 15 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Install the passenger seat. NOTE: ● Make sure that the seats are properly secured before riding. ● The rider seat height can be adjusted to change the riding position. (See page 3-16.) 3 1. Projection 2. Seat holder 2. Remove the key. Rider seat To remove the rider seat 1. Remove the passenger seat. 2.
chapter3 Page 16 Thursday, January 12, 2006 11:23 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39632 Adjusting the rider seat height The rider seat height can be adjusted to one of two positions to suit the rider’s preference. The rider seat height was adjusted to the lower position at delivery. 3 1. Rider seat height position adjuster 3. Move the rider seat holder cover to the lower position as shown. 1. Rider seat height position adjuster 2. “H” mark 3. Match mark 5.
chapter3 Page 17 Thursday, January 12, 2006 11:23 AM INSTRUMENT AND CONTROL FUNCTIONS 6. Align the projection on the bottom of the rider seat with the “L” position slot, and then push the rear of the seat down to lock it in place as shown. 6. Align the projection on the bottom of the rider seat with the “H” position slot, and then push the rear of the seat down to lock it in place as shown. 3 1. Rider seat height position adjuster 2. “L” mark 3. Match mark 1. “H” position slot 5.
U3P610E0.book Page 18 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU40250 EAU39480 Storage compartments Accessory box This vehicle is equipped with two storage compartments. Storage compartment A is located under the rider seat. (See page 3-14.) The accessory box is located beside the meter panel. To open the accessory box 1. Insert the key into the main switch, and then turn it to “ON”. 2. Push the accessory box button, and then open the accessory box lid. 3 1.
U3P610E0.book Page 19 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS ECA11800 CAUTION: 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. EWA11421 WARNING ● ● Do not exceed the load limit of 0.3 kg (0.66 lb) for the accessory box. Do not exceed the maximum load of 211 kg (465 lb) (CAL) 212 kg (467 lb) (U49) for the vehicle.
U3P610E0.book Page 20 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39621 Opening and closing the cowlings The cowlings can be tilted back 30 mm (1.18 in) for added ventilation to suit the riding conditions. 3 1. Quick fastener screw 1. Quick fastener screw 2. Pull the cowling to the open position, and then install the quick fastener screws. 2. Push the cowling to the closed position, and then install the quick fastener screws. 1. Closed position 2. Open position 3.
U3P610E0.book Page 21 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39671 EAU14731 Rear view mirrors Adjusting the front fork The rear view mirrors of this vehicle can be folded forward or backward for parking in narrow spaces. Fold the mirrors back to their original position before riding. This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting knobs and compression damping force adjusting screws.
U3P610E0.book Page 22 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3 1. Rebound damping force adjusting knob 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob on each fork leg in direction (a).
U3P610E0.book Page 23 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14911 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting lever and a rebound damping force adjusting knob. For riding solo, move the spring preload adjusting lever in direction (b). For riding with a passenger, move the spring preload adjusting lever in direction (a).
chapter3 Page 24 Thursday, January 12, 2006 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS ● ● 3 Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. 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.
chapter3 Page 25 Thursday, January 12, 2006 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15321 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
U3P610E0.book Page 26 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective.
U3P610E0.book Page 27 Thursday, December 22, 2005 11:16 AM INSTRUMENT AND CONTROL FUNCTIONS EAU39651 EWA14360 Auxiliary DC jack WARNING This vehicle is equipped with an auxiliary DC jack in the accessory box. A 12-V accessory connected to the auxiliary jack can be used when the key is in the “ON” position and should only be used when the engine is running. To prevent electrical shock or shortcircuiting, make sure that the cap is installed when the auxiliary DC jack is not being used.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-13 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-13 Final gear oil • Check vehicle for oil leakage. 6-15 Coolant • Check coolant level in reservoir.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-20, 6-27 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU40280 Starting the engine EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 5 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U3P610E0.book Page 4 Thursday, December 22, 2005 11:16 AM OPERATION AND IMPORTANT RIDING POINTS ECA10331 EAU17212 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.
U3P610E0.book Page 4 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL No. 6 ITEM ROUTINE 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation and fluid leakage. • Correct if necessary.
U3P610E0.book Page 5 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
U3P610E0.book Page 6 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month 18 * Rear suspension link pivots • Apply lithium-soap-based grease lightly. 19 Engine oil • Change (warm engine before draining). √ 20 * Engine oil filter cartridge • Replace.
U3P610E0.book Page 7 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM 26 * Lights, signals and switches ROUTINE • Check operation. • Adjust headlight beam.
U3P610E0.book Page 8 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel E 1. Panel A 2. Bolt 3. Quick fastener To install the panel Place the panel in the original position, and then install the bolts and the quick fastener. 6 1. 2. 3. 4.
U3P610E0.book Page 9 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR To install the panel 1. Place the panel in the original position, and then install the bolt and quick fastener. 1. 2. 3. 4. Panel B Bolt Screw Quick fastener 1. Panel C 2. Bolt 3. Quick fastener ECA15420 To install the panel 1. Place the panel in the original position, and then install the bolt, screw and the quick fasteners. 2. Close the accessory box lid.
U3P610E0.book Page 10 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR To install the panel 1. Place the panel in the original position, and then install the bolts and quick fastener. 1. Panel D 2. Bolt 3. Quick fastener 1. Panel E 2. Bolt 3. Quick fastener screw ECA15420 CAUTION: 6 Do not remove the headlight beam adjusting cable. 1. Panel D 2. Install panels B and C. EAU39591 To install the panel 1.
chapter6 Page 11 Thursday, January 12, 2006 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU39601 EAU19642 Checking the spark plugs Panel F To remove the panel 1. Remove the seats. (See page 3-14.) 2. Remove the bolt and the quick fastener screws, and then take the panel off. 2. Install the seats. 1. Panel F 2. Bolt 3. Quick fastener screw To install the panel 1. Place the panel in the original position, and then install the bolt and the quick fastener screws.
U3P610E0.book Page 12 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19681 Specified spark plug: NGK/CR8E DENSO/U24ESR-N Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.
U3P610E0.book Page 13 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19881 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3.
U3P610E0.book Page 14 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) 7. Install the engine oil drain bolt, and then tighten it to the specified torque. 1. Oil filter cartridge 2. Oil filter wrench 6 NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Check the washer for damage and replace it if necessary. 1.
U3P610E0.book Page 15 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11620 CAUTION: ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase.
U3P610E0.book Page 16 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. 6 1. Final gear oil filler bolt 2. Final gear oil drain bolt 3. Correct oil level 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4.
U3P610E0.book Page 17 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The coolant should be between the minimum and maximum level marks. EAU39510 To check the coolant level The coolant level should be checked as follows before each ride.
U3P610E0.book Page 18 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● wise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. EAU33030 EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot.
U3P610E0.book Page 19 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown. If the air filter element is damaged, replace it. ECA15410 CAUTION: Make sure that the fuel tank breather/overflow hose is not pinched. 1. Air filter case cover 2. Screw 4. Pull the air filter element out. 6. Insert the air filter element into the air filter case. 1. Fuel tank breather/overflow hose ECA10480 CAUTION: ● ● 1. Air filter element 5.
U3P610E0.book Page 20 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21381 Checking the throttle cable free play EAU21401 EAU21750 Valve clearance Tires 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.
U3P610E0.book Page 21 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 270 kPa (39 psi) (2.70 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) 90–211 kg (198–465 lb) (CAL) 90–212 kg (198–467 lb) (U49): Front: 270 kPa (39 psi) (2.70 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 270 kPa (39 psi) (2.70 kgf/cm²) Rear: 290 kPa (42 psi) (2.
U3P610E0.book Page 22 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10580 WARNING ● ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U3P610E0.book Page 23 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● “broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions.
U3P610E0.book Page 24 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. 6 EAU22072 Clutch lever Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride.
U3P610E0.book Page 25 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU22500 EAU40270 Checking the brake and clutch fluid levels Front brake Rear brake pads EAU22420 Front brake pads 1.
U3P610E0.book Page 26 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR Clutch ● ● 1. Minimum level mark 6 Insufficient brake fluid may allow air to enter the brake or clutch systems, possibly causing them to become ineffective. 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.
U3P610E0.book Page 27 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22750 EAU23090 EAU23111 Changing the brake and clutch fluids Checking and lubricating the cables Checking and lubricating the throttle grip and cable Have a Yamaha dealer change the brake and clutch fluids at the intervals specified in the NOTE after the periodic maintenance and lubrication chart.
U3P610E0.book Page 28 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 Checking and lubricating the brake and shift pedals EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the brake and clutch levers Brake lever Clutch lever 6 The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U3P610E0.book Page 29 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23211 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAUM1650 Checking and lubricating the centerstand and sidestand Lubricating the swingarm pivots The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
U3P610E0.book Page 30 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23250 Lubricating the rear suspension EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over.
U3P610E0.book Page 31 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
U3P610E0.book Page 32 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU39520 Battery battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. EWA10760 WARNING ● 1. Battery 2. Positive battery terminal 3. Negative battery terminal 6 The battery is located under panel A. (See page 6-8.
U3P610E0.book Page 33 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU23656 Replacing the fuses The main fuse, the fuse boxes and the ABS motor fuse are located under panel A. (See page 6-8.) 1. 2. 3. 4. Main fuse Fuse box ABS motor fuse ABS motor spare fuse 1. Fuse box 2. Right radiator fan fuse 3. Left radiator fan fuse 4.
U3P610E0.book Page 34 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6 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. Specified 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 Backup fuse: 10.0 A Hazard fuse: 10.0 A Fuel injection system fuse: 15.
U3P610E0.book Page 35 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Headlight bulb holder 2. Headlight bulb EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.
U3P610E0.book Page 36 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU39880 Front turn signal light If a front turn signal light does not come on, have a Yamaha dealer check its electrical circuit or replace the bulb. EAU27001 Replacing a rear turn signal light bulb or a tail/brake light bulb 1. Remove the passenger seat. (See page 3-14.) 2. Remove the socket (together with the bulb) by turning it counterclockwise. 6 1. Turn signal light bulb socket 2.
U3P610E0.book Page 37 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 Replacing the license plate light bulb 1. Remove the license plate light unit by removing the screws. 3. Remove the defective bulb by pulling 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. Screw 2. License plate light unit 2.
U3P610E0.book Page 38 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U3P610E0.book Page 39 Thursday, December 22, 2005 11:16 AM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU26060 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a 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.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM MOTORCYCLE CARE AND STORAGE ● Avoid 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.
U3P610E0.book Page 4 Thursday, December 22, 2005 11:16 AM MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/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. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM SPECIFICATIONS Dimensions: Overall length: 2230 mm (87.8 in) Overall width: 750 mm (29.5 in) Overall height: 1450 mm (57.1 in) Seat height: 800 mm (31.5 in) Wheelbase: 1545 mm (60.8 in) Ground clearance: 130 mm (5.12 in) Minimum turning radius: 3100 mm (122.0 in) Weight: With oil and fuel: 291.0 kg (642 lb) (U49) 292.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM SPECIFICATIONS 5th: 26/28 (0.929) Chassis: Frame type: Diamond Caster angle: 26.00 ° Trail: 109.0 mm (4.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM SPECIFICATIONS Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: 8 Headlight: 12 V, 60 W/55.0 W × 2 Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Front turn signal/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 License plate light: 12 V, 5.
U3P610E0.book Page 1 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification 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. The vehicle identification number is stamped into the steering head pipe.
U3P610E0.book Page 2 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26520 Model label 1. Model label The model label is affixed to the frame under the passenger seat. (See page 3-14.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U3P610E0.book Page 3 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U3P610E0.book Page 5 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U3P610E0.book Page 7 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U3P610E0.book Page 9 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U3P610E0.book Page 10 Thursday, December 22, 2005 11:16 AM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed 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.
U3P610E0.book Page 1 Thursday, January 12, 2006 1:31 PM INDEX A ABS ...................................................... 3-12 ABS warning light ................................... 3-2 Accessories and replacement parts ..... 6-23 Accessory box ...................................... 3-18 Air filter element, cleaning .................... 6-18 Auxiliary DC jack .................................. 3-27 Engine trouble warning light ....................3-2 F Final gear oil......................................
U3P610E0.book Page 2 Thursday, January 12, 2006 1:31 PM INDEX T Tachometer............................................. 3-3 Throttle cable free play, checking ......... 6-20 Throttle grip and cable, checking and lubricating ........................................... 6-27 Tires ...................................................... 6-20 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-37 Troubleshooting charts .........................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.01-1.
