Read this manual carefully before operating this vehicle.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM EAU50920 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. YAMAHA MOTOR ELECTRONICS CO., LTD. 1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY We Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM INTRODUCTION EAU10102 Welcome to the Yamaha world of motorcycling! As the owner of the XJ6SA, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XJ6SA.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM IMPORTANT MANUAL INFORMATION EAU10200 XJ6SA OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, July 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Immobilizer system .........................3-1 Main switch/steering lock ................
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM TABLE OF CONTENTS Checking the front fork .................6-33 Checking the steering ...................6-33 Checking the wheel bearings .......6-34 Battery ..........................................6-34 Replacing the fuses ......................6-35 Replacing the headlight bulb ........6-37 Replacing the tail/brake light bulb ...........................................6-38 Replacing a turn signal light bulb ...........................................
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM SAFETY INFORMATION EAU1028A 1 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. 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.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM SAFETY INFORMATION ● ● Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. • Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. • Know your skills and limits. Staying within your limits may help you to avoid an accident.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM SAFETY INFORMATION 1 Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust.
U36DE0E0.book Page 4 Monday, August 6, 2012 5:14 PM SAFETY INFORMATION ● tents, can create unstable handling or a slow steering response. This vehicle is not designed to pull a trailer or to be attached to a sidecar. Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision. Genuine Yamaha accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by Yamaha for use on your vehicle.
U36DE0E0.book Page 5 Monday, August 6, 2012 5:14 PM 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.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM DESCRIPTION EAU10410 Left view 1 2 3 4,5 6 7 2 10 9 1. 2. 3. 4. 5. 6. 7. 8. 8 Air filter element (page 6-18) Idle adjusting screw (page 6-19) Seat lock (page 3-18) Main fuse (page 6-35) Fuse box (page 6-35) Owner’s tool kit (page 6-2) Storage compartment (page 3-19) Shift pedal (page 3-13) 9. Engine oil filter cartridge (page 6-11) 10.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM DESCRIPTION EAU10420 Right view 1 2 3 4 5 2 11 10 9 8 1. 2. 3. 4. 5. 6. 7. 8. 7 Helmet holder (page 3-18) Battery (page 6-34) Rear brake fluid reservoir (page 6-26) Engine oil filler cap (page 6-11) Radiator cap (page 6-14) Coolant reservoir (page 6-14) Coolant drain bolt (page 6-15) Engine oil dipstick (page 6-11) 6 9. Brake pedal (page 3-14) 10.Rear brake light switch (page 6-25) 11.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 2 1. 2. 3. 4. 5. 6. 7. 8.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10977 Immobilizer system 3 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS ● Keep other immobilizer system keys away from the main switch as they may cause signal interference. EAU10472 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. TIP Be sure to use the standard key (black bow) for regular use of the vehicle.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10684 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering 1 ECA11020 NOTICE 2 Do not use the parking position for an extended length of time, otherwise the battery may discharge. To lock the steering 3 1 2 1. Push. 2. Turn. Push the key in, and then turn it to “OFF” while still pushing it. 1. Push. 2. Turn. 1.
U36DE0E0.book Page 4 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU49392 Indicator lights and warning lights 1 2 345 EAU11060 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. ABS EAU11254 876 1. 2. 3. 4. 5. 6. 7. 8.
U36DE0E0.book Page 5 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10021 NOTICE Do not continue to operate the engine if it is overheating. TIP ● 3 ● For radiator-fan-equipped vehicles, the radiator fan(s) automatically switch on or off according to the coolant temperature in the radiator. If the engine overheats, see page 6-42 for further instructions.
U36DE0E0.book Page 6 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS Display Conditions What to do Under 39 °C (Under 103 °F) Message “Lo” is displayed. OK. Go ahead with riding. 40–116 °C (104–242 °F) Coolant temperature is displayed. OK. Go ahead with riding. 117–134 °C (243–274 °F) Coolant temperature flashes. Warning light comes on. Stop the vehicle and allow it to idle until the coolant temperature goes down. If the temperature does not go down, stop the engine.
U36DE0E0.book Page 7 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11534 3 Engine trouble warning light “ ” This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the self-diagnosis system. (See page 3-10 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”.
U36DE0E0.book Page 8 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU46765 Multi-function meter unit 1 2 3 4 ABS 8 7 6 1. 2. 3. 4. 5. 6. 7. 8.
U36DE0E0.book Page 9 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS Clock 1 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. Odometer and tripmeter modes 3 1. Clock The clock displays when the key is turned to “ON”. In addition, the clock can be displayed for 10 seconds by pushing the “SELECT” button when the main switch is in the “OFF”, “LOCK” or “ ” position. To set the clock 1. Turn the key to “ON”. 2.
U36DE0E0.book Page 10 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases. When the last segment on the left starts flashing, refuel as soon as possible. TIP This fuel meter is equipped with a selfdiagnosis system.
U36DE0E0.book Page 11 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS If a problem is detected in the immobilizer system circuits, the immobilizer system indicator light will flash and the display will indicate an error code. 3 TIP If the display indicates error code 52, this could be caused by transponder interference. If this error code appears, try the following. key and both standard keys to a Yamaha dealer and have the standard keys re-registered.
U36DE0E0.book Page 12 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS Right position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 1. Engine stop switch “ 2. Start switch “ ” / ” EAU12350 Pass switch “ ” Press this switch to flash the headlight. EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam.
U36DE0E0.book Page 13 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12871 Shift pedal EAU26824 Brake lever The brake lever is located on the right side of the handlebar. To apply the front brake, pull the lever toward the throttle grip. 3 1 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever.
U36DE0E0.book Page 14 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU51670 TIP ABS 1 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. Operate the brakes with ABS as you would conventional brakes.
U36DE0E0.book Page 15 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS wheel hubs may be damaged, resulting in improper performance of the ABS system. 1 EAU13074 TIP 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 tank cap 2 EWA11091 WARNING 3 Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard. 1. Fuel tank cap lock cover 2.
U36DE0E0.book Page 16 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13221 Fuel 1 Make sure there is sufficient gasoline in the tank. 2 EWA10881 ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1.
U36DE0E0.book Page 17 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU51190 Fuel tank breather hose and overflow hose EAU13433 NOTICE This model is equipped with a catalytic converter in the exhaust system. Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. EWA10862 WARNING 2 3 1 1. Fuel tank breather hose and overflow hose 2. Clamp Before operating the motorcycle: ● Check each hose connection.
U36DE0E0.book Page 18 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU32980 EAU46751 Seat Helmet holder 1 To remove the seat 1. Insert the key into the seat lock, and then turn it counterclockwise. 2 2 1 2 3 1. Projection 2. Seat holder 1 1. Seat lock 2. Unlock. 2. While holding the key in that position, lift the rear of the seat up, and then pull the seat off. 2. Push the rear of the seat down to lock it in place. 3. Remove the key.
U36DE0E0.book Page 19 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14453 1 2 3 Storage compartment 1 3 1. Helmet 2. Helmet holding cable 3. Helmet holder 3. Place the helmet on the right side of the vehicle, and then install the seat. WARNING! Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.
U36DE0E0.book Page 20 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU46831 EAU47260 Handlebar position Rear view mirrors The handlebar can be adjusted to one of two positions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handlebar. The rear view mirrors of this vehicle can be folded forward for parking in narrow spaces. Fold the mirrors back to their original position before riding.
U36DE0E0.book Page 21 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS ● 3 2 ● (b) 1 (a) 3 4 1. 2. 3. 4. Extension bar Special wrench Spring preload adjusting ring Position indicator ● ● Spring preload setting: Minimum (soft): 1 Standard: 3 Maximum (hard): 7 Do not tamper with or attempt to open the cylinder assembly. Do not subject the shock absorber assembly to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.
U36DE0E0.book Page 22 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS this system regularly and have a Yamaha dealer repair it if it does not function properly. EAU44902 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.
U36DE0E0.book Page 23 Monday, August 6, 2012 5:14 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? WARNING • The vehicle must be placed on the center- ”. stand during this inspection. • If a malfunction is noted, have a Yamaha dealer check the system before riding.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING 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.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE 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 specified brake fluid to specified level. Check hydraulic system for leakage. Clutch • • • • Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. — Instruments, lights, signals and switches • Check operation. • Correct if necessary. — Sidestand switch • Check operation of ignition circuit cut-off system. • If system is not working correctly, have Yamaha dealer check vehicle.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU15951 EAU47150 EAU54581 Starting the engine Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM OPERATION AND IMPORTANT RIDING POINTS a warning or indicator light remains on, see page 3-4 for the corresponding warning and indicator light circuit check. The ABS warning light should come on when the main switch is turned to “ON” and then go off after traveling at a speed of 10 km/h (6 mi/h) or higher. tery. Do not crank the engine more than 10 seconds on any one attempt.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE ● 5 ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U36DE0E0.book Page 4 Monday, August 6, 2012 5:14 PM OPERATION AND IMPORTANT RIDING POINTS 1600 km (1000 mi) and beyond The vehicle can now be operated normally. ECA10310 NOTICE ● ● Keep the engine speed out of the tachometer red zone. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 EWA15122 EAU17302 WARNING 6 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39691 Owner’s tool kit 1 1. Owner’s tool kit The owner’s tool kit is located on the bottom of 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.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU46861 TIP ● ● ● The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead. From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
U36DE0E0.book Page 4 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU1770F General maintenance and lubrication chart ODOMETER READING NO. 1 2 ITEM CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) ANNUAL CHECK √ Air filter element • Replace. Clutch • Check operation. • Adjust. √ √ √ √ √ • Check operation, fluid level and vehicle for fluid leakage.
U36DE0E0.book Page 5 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM 10 * Swingarm 11 Drive chain 12 * Steering bearings 6 13 * Chassis fasteners CHECK OR MAINTENANCE JOB 1000 km (600 mi) • Check operation and for excessive play. 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) √ √ √ √ ANNUAL CHECK • Lubricate with lithium-soap-based grease. Every 50000 km (30000 mi) • Check chain slack, alignment and condition.
U36DE0E0.book Page 6 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM 20 * Front fork CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) • Check operation and for oil leakage. √ √ √ √ √ √ √ √ √ √ √ √ 21 * Shock absorber assembly • Check operation and shock absorber for oil leakage. 22 Engine oil • Change. • Check oil level and vehicle for oil leakage.
U36DE0E0.book Page 7 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18680 TIP ● ● Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level.
U36DE0E0.book Page 8 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18712 1 Removing and installing cowlings and panels EAU46770 2 Panel A To remove the panel Remove the bolt and the quick fastener, and then take the panel off. The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1 2 1 2 1. Panel A 2. Cowling C 3 1 2 1.
U36DE0E0.book Page 9 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT To install a panel Place the panel in the original position, and then install the bolts. 1 2 2 1 1. Panel B 2. Bolt 6 2. Push the panel outwards to unhook the projection underneath the panel, and then pull the panel off as shown. 1 2 1. Cowling A 2. Bolt EAU46740 Cowling A To remove the cowling Remove the bolts, and then take the cowling off.
U36DE0E0.book Page 10 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 1 2 2. Place the cowling in the original position, and then install the bolts and the quick fastener. 3 1. Cowling B 2. Bolt 3. Quick fastener 3. Disconnect the turn signal light lead connectors. 3. Install panel B or C. 1 1. Turn signal light lead connector To install a cowling 1. Connect the turn signal light lead connectors.
U36DE0E0.book Page 11 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. EAU47551 TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
U36DE0E0.book Page 12 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 6. Insert and tighten the engine oil dipstick, and then install and tighten the oil filler cap. 1 2 3 1. Engine oil dipstick 2. Maximum level mark 3. Minimum level mark 5. If the engine oil is at or below the minimum level mark, remove the oil filler cap, and then add sufficient oil of the recommended type to raise it to the correct level.
U36DE0E0.book Page 13 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.50 L (2.64 US qt, 2.20 Imp.qt) With oil filter cartridge replacement: 2.80 L (2.96 US qt, 2.46 Imp.qt) TIP An oil filter wrench is available at a Yamaha dealer. 6. Apply a thin coat of clean engine oil to the O-ring of the new oil filter cartridge. 1 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.
U36DE0E0.book Page 14 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 10. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately 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.
U36DE0E0.book Page 15 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 1 2 3 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. [ECA10472] 1. Coolant reservoir cap 2. Coolant reservoir breather hose 3. Guide 6 4. Add coolant to the maximum level mark, and then install the coolant reservoir cap.
U36DE0E0.book Page 16 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Remove the coolant reservoir breather hose from the guide, and then remove the coolant reservoir cap. 9. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. 10. Install the coolant drain bolt and its new gasket, and then tighten the bolt to the specified torque. 1 1 2 2 3 1. Coolant reservoir cap 2. Coolant reservoir breather hose 3. Guide 6.
U36DE0E0.book Page 17 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT Antifreeze/water mixture ratio: 1:1 Recommended antifreeze: High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Coolant quantity: Radiator capacity (including all routes): 2.00 L (2.11 US qt, 1.76 Imp.qt) Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt, 0.22 Imp.qt) 6 13. Install the radiator cap. 14. Install the coolant reservoir cap. 15.
U36DE0E0.book Page 18 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32887 Replacing the air filter element The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-18.) 2. Remove panels B and C. (See page 6-8.) 3.
U36DE0E0.book Page 19 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT the engine, otherwise fuel may leak, creating a fire hazard. [EWA12463] EAU34301 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment.
U36DE0E0.book Page 20 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21384 Checking the throttle grip free play EAU21401 EAU21776 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. Tires are the only contact between the vehicle and the road.
U36DE0E0.book Page 21 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT weight of rider, passenger, cargo, and accessories approved for this model. 6 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 225 kPa (2.25 kgf/cm², 33 psi) Rear: 250 kPa (2.50 kgf/cm², 36 psi) 90–184 kg (198–406 lb): Front: 250 kPa (2.50 kgf/cm², 36 psi) Rear: 290 kPa (2.90 kgf/cm², 42 psi) High-speed riding: Front: 225 kPa (2.25 kgf/cm², 33 psi) Rear: 250 kPa (2.
U36DE0E0.book Page 22 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT Tire information EWA10481 WARNING ● ● 1. Tire air valve 2. Tire air valve core 3. Tire air valve cap with seal This motorcycle is equipped with tubeless tires, tire air valves and cast wheels. Tires age, even if they have not been used or have only been used occasionally. Cracking of the tread and sidewall rubber, sometimes accompanied by carcass deformation, is an evidence of ageing.
U36DE0E0.book Page 23 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● ● 6 “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.
U36DE0E0.book Page 24 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU37913 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 loosen the clutch cable. 2. Remove cowling B. (See page 6-8.) 3. Loosen the locknut further down the clutch cable. 4. To increase the clutch lever free play, turn the clutch lever free play adjusting nut in direction (a).
U36DE0E0.book Page 25 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT braking performance, which may result in loss of control and an accident. EAU36503 Brake light switches The brake light, which is activated by the brake pedal and brake lever, should come on just before braking takes effect. If necessary, have a Yamaha dealer adjust the brake light switches.
U36DE0E0.book Page 26 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU46291 Rear brake pads EAU43112 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid level with the top of the reservoir level. Replenish the brake fluid if necessary. Rear brake 1 Front brake 1 1.
U36DE0E0.book Page 27 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● ● ● ● 6 Clean the filler cap before removing. Use only DOT 4 brake fluid from a sealed container. Use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage. Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction. Be careful that water or dust does not enter the brake fluid reservoir when refilling.
U36DE0E0.book Page 28 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22794 To check the drive chain slack 1. Place the motorcycle on the centerstand. 2. Shift the transmission into the neutral position. 3. Measure the drive chain slack as shown. 1 1. Drive chain slack Drive chain slack: 45.0–55.0 mm (1.77–2.
U36DE0E0.book Page 29 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23025 Cleaning and lubricating the drive chain 2 1 1. Drive chain puller 2. Alignment marks 6 5. Take the motorcycle off the centerstand, and then put the sidestand down. 6. Tighten the axle nut, and then tighten the locknuts to the specified torques. Tightening torques: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lbf) Locknut: 16 Nm (1.6 m·kgf, 12 ft·lbf) 7.
U36DE0E0.book Page 30 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU49920 EAU23095 EAU44273 Checking and lubricating the cables Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
U36DE0E0.book Page 31 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23143 Recommended lubricant: Lithium-soap-based grease Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U36DE0E0.book Page 32 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23213 Checking and lubricating the centerstand and sidestand EAUM1652 Recommended lubricant: Lithium-soap-based grease 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.
U36DE0E0.book Page 33 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 EAU45511 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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.
U36DE0E0.book Page 34 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings EAU50290 Battery 2 3 1 The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery 2. Negative battery lead (black) 3.
U36DE0E0.book Page 35 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ECA16521 NOTICE To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. 6 To store the battery 1.
U36DE0E0.book Page 36 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 12 avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] 34 5 5 6 7 8 9 10 11 1. 2. 3. 4. 5. 6. 7. 8. 9. Taillight fuse ABS control unit fuse ABS solenoid fuse ABS motor fuse Spare fuse Headlight fuse Ignition fuse Signaling system fuse Backup fuse (for clock and immobilizer system) 10.Fuel injection system fuse 11.Radiator fan fuse If a fuse is blown, replace it as follows. 1.
U36DE0E0.book Page 37 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Unhook the headlight bulb holder, and then remove the burnt-out bulb. EAU47601 Replacing the headlight bulb This model is equipped with a halogen bulb headlight. If the headlight bulb burns out, replace it as follows.
U36DE0E0.book Page 38 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU47021 EAU24204 Replacing the tail/brake light bulb 1. Remove the seat. (See page 3-18.) 2. Remove the tail/brake light bulb socket (together with the bulb) by turning it counterclockwise. Replacing a turn signal light bulb 1 1. Remove the turn signal light lens by removing the screw. 2 1 1 1. Tail/brake light bulb 2. Tail/brake light bulb socket 4. Insert a new bulb into the socket. 5.
U36DE0E0.book Page 39 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24313 1 Replacing the license plate light bulb 1. Remove the license plate light unit by removing the screws. 1 1 2 1. Turn signal light bulb 6 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw. NOTICE: Do not overtighten the screw, otherwise the lens may break. [ECA11191] 1. License plate light bulb socket 2.
U36DE0E0.book Page 40 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU39020 Auxiliary light bulb EAU25871 Troubleshooting 1 1. Auxiliary light bulb If the auxiliary light does not come on, have a Yamaha dealer check the electrical circuit or replace the bulb. Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
U36DE0E0.book Page 41 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU42364 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough fuel. Check the battery. There is no fuel. Supply fuel. Check the fuel level in the fuel tank. 2. Battery The engine does not start. Check the battery. The engine turns over quickly. The battery is good. The engine turns over slowly.
U36DE0E0.book Page 42 Monday, August 6, 2012 5:14 PM PERIODIC MAINTENANCE AND ADJUSTMENT 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.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM MOTORCYCLE CARE AND STORAGE ● ● ● off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM MOTORCYCLE CARE AND STORAGE ers, test an area of the windshield which does not affect your visibility and which cannot be easily recognized. 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system.
U36DE0E0.book Page 4 Monday, August 6, 2012 5:14 PM MOTORCYCLE CARE AND STORAGE EAU26182 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. Be sure the engine and the exhaust system are cool before covering the motorcycle. ECA10810 NOTICE ● ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
U36DE0E0.book Page 5 Monday, August 6, 2012 5:14 PM MOTORCYCLE CARE AND STORAGE TIP Make any necessary repairs before storing the motorcycle.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM SPECIFICATIONS Dimensions: Overall length: 2120 mm (83.5 in) Overall width: 770 mm (30.3 in) Overall height: 1210 mm (47.6 in) Seat height: 785 mm (30.9 in) Wheelbase: 1440 mm (56.7 in) Ground clearance: 140 mm (5.51 in) Minimum turning radius: 2800 mm (110.
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM SPECIFICATIONS 2nd: 1.947 (37/19) 3rd: 1.556 (28/18) 4th: 1.333 (32/24) 5th: 1.190 (25/21) 6th: 1.083 (26/24) Chassis: Frame type: Diamond Caster angle: 26.00 ° Trail: 103 mm (4.
U36DE0E0.book Page 3 Monday, August 6, 2012 5:14 PM SPECIFICATIONS Charging system: AC magneto Battery: Model: GT12B-4 Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60.0 W/55.0 W × 1 Tail/brake light: 12 V, 5.0 W/21.0 W × 1 Front turn signal light: 12 V, 10.0 W × 2 Rear turn signal light: 12 V, 10.0 W × 2 Auxiliary light: 12 V, 5.0 W × 1 License plate light: 12 V, 5.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM CONSUMER INFORMATION EAU48612 Identification numbers EAU26400 Vehicle identification number Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: 9 EAU26480 Model label 1 1 1. Vehicle identification number 1.
U36DE0E0.book Page 1 Monday, August 6, 2012 5:14 PM INDEX A E ABS ...................................................... 3-14 ABS warning light ................................... 3-7 Air filter element, replacing ................... 6-18 Auxiliary light bulb................................. 6-40 Engine break-in .......................................5-3 Engine idling speed...............................6-19 Engine oil and oil filter cartridge ............6-11 Engine stop switch ........................
U36DE0E0.book Page 2 Monday, August 6, 2012 5:14 PM INDEX Tires ...................................................... 6-20 Tool kit .................................................... 6-2 Troubleshooting .................................... 6-40 Troubleshooting charts ......................... 6-41 Turn signal indicator light ........................ 3-4 Turn signal light bulb, replacing ............ 6-38 Turn signal switch ................................. 3-12 V Valve clearance .......................
U36DE0E0.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012.08-0.
