Yamaha Tenere XT660Z (2012) manual

2B D-F8199-2 0 XT660Z OWNER’S MANUAL Read this manual carefully befor e operating this vehicle. Australia 4/8/10 18:04 Página 1[...]

EAU46090 Read this manual carefully befor e operating this vehicle. This manual should stay with this vehicle if it is sold. XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 2[...]

INTRODUCTION EAU10102 W elcome to the Y amaha world of motorcycling! As the o wner of the XT660Z T énéré, y ou are benefiting from Y amaha's vast experience and ne west technology regarding the design and manuf acture of high-quality products, which ha ve earned Y amaha a reputation f or dependability . Please take the time to read this man[...]

IMPOR T ANT MANUAL INFORMA TION P ar ticularly impor tant information is distinguished in this manual b y the follo wing notations: WA RN IN G 0 TIP This is the safety alert symbol. It is used to alert you to potential personal injury haz- ards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WAR NING indic ate[...]

IMPOR T ANT MANUAL INFORMA TION EAUB101 1 XT660Z OWNER'S MANUAL ©20 12 by MBK INDUSTRIE 1 st edition, March 201 2 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly pr ohibited. Printed in France . Australia 5/8/10 16:19 Página 5[...]

T ABLE OF CONTENTS L OC A T IO N O F IM P O R T AN T L A BE L S ...1-1 SAFETY INFORMA TION .....................2-1 Be a Responsible Owner ..................2-1 Saf e riding .........................................2-1 Protective apparel .............................2-2 A void Carbon Mono xide P oisoning ...2-2 Loading .............................[...]

Checking and lubricating the cables .................................7-25 Checking and lubricating the throttle grip and cable ........7-26 Checking and lubricating the brake and clutch levers ......................7-26 Lubricating the brake pedal ............7-27 Checking and lubricating the sidestand ............................7-27 Lubricating t[...]

1-1 1 2 3 4 5 6 7 8 9 10 LOCA TION OF IMPOR T ANT LABELS EAU10383 Read and understand all of the labels on your v ehicle. They contain impor tant information f or saf e and proper operation of your vehicle . Ne ver remov e an y labels from y our v ehicle. If a label becomes difficult to read or comes off, a replacement label is av ailab le from you[...]

1 2 3 4 5 6 7 8 9 10 LOCA TION OF IMPOR T ANT LABELS 1-2 1 2 3 4 XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 9[...]

SAFETY INFORMA TION EAU10313 Be a Responsible Owner As the v ehicle's o wner , y ou are re- sponsible f or the safe and proper op- eration of y our motorcycle. Motorcycles are single-trac k vehicles . Their safe use and operation are de- pendent upon the use of proper riding techniques as well as the exper tise of the operator . Ev er y oper a[...]

1 2 3 4 5 6 7 8 9 10 • Alwa ys signal before turning or changing lanes . Mak e sure that other motorists can see you. ● The posture of the operator and passenger is impor tant for proper control. • The operator should keep both hands on the handlebar and bo th fe et o n th e op era to r f ootre sts dur ing o peration to maintain control of th[...]

SAFETY INFORMA TION Loading Adding accessories or cargo to your motorcycle can adv ersely aff ect stabil- ity and handling if the weight distribu- tion of the motorcycle is changed. T o av oid the possibility of an accident, use e xtreme caution when adding car- go or accessor ies to your motorcycle. Use e xtra care when riding a motorcy- cle that [...]

1 2 3 4 5 6 7 8 9 10 SAFETY INFORMA TION products or having other modifications perf or med to your vehicle that change any of the vehicle's design or opera- tion characteristics can put you and others at greater r isk of serious injur y or death. Y ou are responsible for in- juries related to changes in the vehi- cle. K eep the following guid[...]

3-1 1 2 3 4 5 6 7 8 9 10 DESCRIPTION EAU10410 Left view 1. Idle adjusting screw (page 7-15) 2. Owner’ s tool kit (page 7-1) 3. Air filter element (page 7-14) 4. Fuse bo x (page 7-31) 5. Seat lock (page 4-14) 6. Sh oc k abs orb er asse mb ly/ spr ing prel oad adj ust ing ring ( pag e 4-1 6) 7. Shift pedal (page 4-10) 8. Engine oil drain bolt (cran[...]

1 2 3 4 5 6 7 8 9 10 3-2 DESCRIPTION 10. Gr ab bar 11. Main fuse (page 7-31) 12. Battery (page 7-30) 13. Rear brake fluid reser voir (page 7-22) 14. Coolant reser voir (page 7-13) 15. F ront br ake fluid reservoir (page 7-22) 16. Coolant drain bolt (page 7-12) 17. Engine oil filter element (page 7-11) 18. Brake pedal (page 4-11) EAU10420 Right view[...]

DESCRIPTION 3-3 1 2 3 4 5 6 7 8 9 10 EAU10430 Controls and instruments 1. Clutch le ver (page 4-10) 2. Left handlebar switches (page 4-9) 3. Multi-function meter unit and warning lights (page 4-3, 4-5) 4. Right handlebar switches (page 4-9) 5. Throttle grip (page 7-16) 6. Brake lev er (page 4-11) 7. Engine oil filler cap/dipstic k (page 7-9) 8. Fue[...]

1 2 3 4 5 6 7 8 9 10 4-1 INSTRUMENT AND CONTROL FUNCTIONS EAU10976 Immobilizer system 1. Code re-registering k ey (red bow) 2. Standard ke ys (black bow) This vehicle is equipped with an im- mobilizer system to help prev ent theft by re-register ing codes in the standard ke ys. This system consists of the fol- lowing. ● a code re-register ing ke [...]

INSTRUMENT AND CONTROL FUNCTIONS 4-2 1 2 3 4 5 6 7 8 9 10 EAU10471 Main switch/steering lock The main s witch/steering loc k controls the ignition and lighting systems, and is used to lock the steering. TIP Be sure to use the standard ke y (b lack bow) f or regular use of the vehicle . T o minimize the risk of losing the code re- registering ke y ([...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-3 T o unlock the steering 1. Push 2. T urn Push the k ey into the main s witch, and then tur n it to “OFF” while still pushing it. EAU10941 F (Parking) The steering is lock ed, and the tail- light, license plate light and auxiliar y lights are on. The hazard lights and turn signal lights c[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-4 1 2 3 4 5 6 7 8 9 10 EAUB1520 Neutral indicator light “ N” This indicator light comes on when the transmission is in the neutral position. The electrical circuit of the neutral indi- cator light can be chec ked by tur ning the k ey to "ON". If the indicator light does not come on for a f ew seconds[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-5 EAUB1501 Multi-function display 1. T achometer 2. Speedometer 3. Odometer 4. T ripmeters/Fuel reserve tr ipmeter 5. Clock 6. Fuel meter 7. “RESET” button 8. “SELECT” button EWA12311 WA RN IN G 0 Be sur e to stop the vehicle before making any setting changes to the multi-function disp[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-6 1 2 3 4 5 6 7 8 9 10 T achometer 1. T achometer 2. Red zone The tachometer allows the rider to monitor the engine speed and keep it within the ideal power r ange. When the k ey is tur ned to "ON", the tachometer needle will s weep once across the r/min range and then return to zero r/min in order to te[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-7 Clock mode 1. Clock 2. “SELECT” button 3. “RESET” button TIP The clock is display ed ev en when the ke y is turned to "OFF". T o set the clock: 1. Push the "SELECT" button for at least f our seconds. 2. When the hour digits star t flash- ing, push the "RESET&[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-8 1 2 3 4 5 6 7 8 9 10 Self-diagnosis devices 1. Engine trouble w arning light “ U ” 2. Immobilizer system indicator light “ ” This model is equipped with a self-di- agnosis de vice f or v ar ious electrical circuits. If any of those circuits are defectiv e, the engine trouble warning light will star t fla[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-9 EAU12348 Handlebar switches Left 1. Pass switch “ 1 ” 2. Dimmer s witch “ 2 / 1 ” 3. Hor n switch “ o ” 4. T urn signal switch “ y ” 5. Hazard s witch “ r ” 5 4 2 1 3 Right 1. Engine stop switch “ I / ” 2. Star t s witch “ J ” EAU12350 Pass switch “ 1 ” Press [...]

INSTRUMENT AND CONTROL FUNCTIONS 4-10 1 2 3 4 5 6 7 8 9 10 EAU12733 Hazard switch “ r ” With the ke y in the “ON” or F position, use this s witch to turn on the hazard lights (simultaneous flashing of all turn signal lights). The hazard lights are used in case of an emergency or to w ar n other drivers when your vehicle is stopped where it [...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-11 EAU26823 Brake lever 1. Brake lev er 2. P osition adjusting dial 3. Arrow mar k 4. Distance The brake lev er is located at the r ight handleb ar gr ip . T o apply the front brak e, pull the lev er tow ard the han- dlebar grip . The brak e le ver is equipped with a po- sition adjusting dial.[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-12 1 2 3 4 5 6 7 8 9 10 T o close the fuel tank cap 1. Push the fuel tank cap into posi- tion with the key inser ted in the lock. 2. T ur n the ke y counterclockwise to the original position, remov e it, and then close the lock co ver . TIP The fuel tank cap cannot be closed unless the ke y is in the lock. In addi[...]

yo ur sk in , was h wi th s oap a nd water . If gasoline spills on your clothing, change your clothes. EAU13390 ECA11400 Use onl y u nlea ded gaso lin e. The use of l eade d gas oli ne wi ll ca use seve re dam age to in ternal en gine pa rts, suc h as t he valv es and pist on ring s, as we ll as to th e exha ust sy stem . Y our Y amaha engine has b[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-14 1 2 3 4 5 6 7 8 9 10 T o install the seat 1. Projections 2. Seat holders 1. Inser t the projection on the front of the seat into the seat holder as shown. 2. Push the rear of the seat down to lock it in place . 3. Remove the k ey . TIP Make sure that the seat is properly se- cured bef ore riding. EAU32980 Seat [...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 4-15 EAUB1550 Adjusting the front fork 1. Spring preload adjusting bolt (a) Increasing the spring preload (b) Decreasing the spring preload This front fork is equipped with spr ing preload adjusting bolt. EWA10180 WA RN IN G 0 Always adjust both fork legs equal- ly , ot herwise poor handl ing an[...]

INSTRUMENT AND CONTROL FUNCTIONS 4-16 1 2 3 4 5 6 7 8 9 10 Adjust the spring preload as follo ws. T o increase the spr ing preload and thereby harden the suspension, turn the adjusting ring in direction (a). T o decrease the spring preload and thereby soften the suspension, tur n the adjusting ring in direction (b). TIP Align the appropr iate notch[...]

EWA10240 WA RN IN G 0 The v ehicle m ust not be ri dden with th e si destand do wn, or if the s id e st an d c a nn o t b e p ro pe r ly moved up (or does not st ay up), other wise the sidestand could con- tact the ground an d d istract the operat or , resul ting in a possi ble loss of c ontrol. Y amah a’ s ig nition circuit c ut-off syste m has [...]

INSTRUMENT AND CONTROL FUNCTIONS WA RN IN G 0 If a malfunction is noted, have a Y amaha dealer check the system before riding. 4-18 1 2 3 4 5 6 7 8 9 10 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ I ” . 3. T ur n the ke y on. 4. Shift the transmission into the neutral position. 5.[...]

EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Alwa ys follo w the in- spection and maintenance procedures and schedules described in the Owner's Manual. EWA11151 WA RN IN G 0 Failure to inspect or maintain the vehicle pr operly incr eases the possibility of an accident or equipment [...]

EAU15605 Before using this vehicle, check the following points: ITEM CHECKS P AGE • Check fuel level in fuel tank. • Refuel if necessary . Fuel • Check fuel line for leakage. 4-12, 4-13 • Check the fuel tank breather/overflow hose for obstructions, cracks or damage, and check the hose connection. • Check oil level in oil tank. Engine oil [...]

1 2 3 4 5 6 7 8 9 10 FOR YOUR SAFETY – PRE-OPERA TION CHECKS 5-3 ITEM Clutch Throttle grip Control cables Drive chain Wheels and tires Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners CHECKS • Check operation. • Lubricate cable if necessar y . • Check le ver free pla y . • Adjust if necessar y . • Make sure tha[...]

FOR YOUR SAFETY – PRE-OPERA TION CHECKS 5-4 1 2 3 4 5 6 7 8 9 10 ITEM Instruments, lights, signals and switches Sidestand switch CHECKS • Check operation. • Correct if necessar y . • Check operation of ignition circuit cut-off system. • If system is not working correctly , hav e Y amaha dealer check vehicle . P AGE 4-3, 4-9 4-17 XT660Z 05[...]

1 2 3 4 5 6 7 8 9 10 OPERA TION AND IMPOR T ANT RIDING POINTS EAU15951 Rea d th e Own er's Man ual care ful ly to bec ome fa mil iar with all contr ols . If the re is a co ntro l o r fu ncti on yo u d o no t und ers tand , as k y ou r Y ama ha deal er . EWA10271 WA RN IN G 0 Failure to familiarize yourself with the contr ols can lead to loss o[...]

OPERA TION AND IMPOR T ANT RIDING POINTS 3. Star t the engine by pushing the star t s witch. TIP If the engine f ails to star t, release the start s witch, wait a f ew seconds , and then tr y again . Each starting attemp t shoul d be as short as possib le to pre- serve the battery . Do not crank the en- gine more than 10 seconds on an y one attem p[...]

ECA10260 CAUTION:  Even with the transmission in the neu tral pos itio n, d o n ot coast for long periods of time with the engine off, and do not tow the motor cycle for long distances. The transmission is properly lubricated only when the engine is running. Inade- quate lubrication may damage the transmission.  Always use the clutch while ch[...]

EAU17101 0-1000 km (0-600 mi) Av oi d p ro lo ng ed o pe ra ti on ab ov e 4500 r/min. NOTICE: After 1000 km (600 mi) of operation, the engine oil must be changed, and the oil filter element replaced. 1000-1600 km (600-1000 mi) Av oi d p ro lo ng ed o pe ra ti on ab ov e 6000 r/min. 1600 km (1000 mi) and beyond The vehicle can now be operated nor- m[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17241 P eriodic inspection, adjustment, and lubrication will keep your v ehicle in the saf est and most efficient condition possible . Safety is an obligation of the vehicle owner/operator . The most im- por tant points of v ehicle inspection, adjustment, and lubrication are ex- plained on[...]

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. ● F rom 50000 km (30000 mi), repeat the maintenance inter v als star ting from 10000 km (6000 mi). ● Items marked with an asterisk shoul[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-3 NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 00 0 k m 1 00 0 0 k m 20 00 0 k m 30 0 00 km 40 0 0 0 k m ( 60 0 m i ) (6 0 00 mi ) (1 20 0 0 m i ) ( 1 80 0 0 m i) ( 24 0 00 mi) ANNUAL CHECK √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ?[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-4 1 2 3 4 5 6 7 8 9 10 NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 00 0 k m 1 00 0 0 k m 20 00 0 k m 30 0 00 km 40 0 00 k m ( 60 0 m i ) (6 0 00 mi ) (1 20 0 0 m i ) ( 1 80 0 0 m i) ( 24 0 00 m i) ANNUAL CHECK √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ?[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-5 7-5 EAUM1890 TIP ● Replace the air filter element more frequently if you are riding in unusually w et or dusty areas. ● Hydraulic brak e ser vice ● Regularly check and, if necessar y , correct the brak e fluid lev el. ● Every two years replace the internal components of the brake [...]

PERIODIC MAINTENANCE AND ADJUSTMENT EAU18722 Removing and installing the cowling and panels The cowling and panels shown need to be remov ed to perf orm some of the maintenance jobs descr ibed in this chapter . Refer to this section each time the cowling or a panel needs to be remov ed and installed. EAUB1540 Panel A and B 1. Panel mounting bolt A.[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-7 Panel E and F 1. Panel mounting bolt 2. Quick f astener E. Right panel F . Left panel T o remov e one of the panels 1. Remove the bolts . 2. Remove the quick f astener and then pull the pa nel off at the areas shown. T o install the panel 1. Place the panel in the original posi- tion. 2. [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-8 1 2 3 4 5 6 7 8 9 10 2. Remove the spark plug as shown, with the spar k plug wrench includ- ed in the owner’ s tool kit. T o check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehi- cle is ridden nor mal[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-9 EAUB1560 Engine oil and oil filter element T he en g in e oi l le v el sh o u ld be ch e c k e d b ef or e e a c h ri d e . In ad d i ti o n, th e oi l m u s t b e c ha n ge d an d t h e o il fi l te r el e me n t r e- p la c ed a t th e in t erv al s sp e ci f ie d in t he pe ri o di c m[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-10 1 2 3 4 5 6 7 8 9 10 T o change the engine oil (with or without oil filter element replacement) 1. Mounting screw 2. Engine guard 1. Sta r t the eng in e, wa rm it up fo r se v- er al m in ut es , an d t he n turn i t o ff . 2. T o reach the drain bolt of the crankcase and the drain bolt of the oil tank, rem[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-11 Tightening torques: Oil filter element cov er bolt: 10 Nm (1.0 m·kgf , 7.2 ft·lbf) Oil filter element drain bolt: 10 Nm (1.0 m·kgf , 7.2 ft·lbf) Tightening torques: Engine oil drain bolt (crankcase): 30 Nm (3.0 m·kgf , 22 ft·lbf) Engine oil drain bolt (oil tank): 18 Nm (1.8 m·kgf [...]

ECAM1060 CAUTION: The engine oil tank must be filled in 2 steps. First, fill the engine oil tank with 1.90 L (2.0 US qt) (1.67 Imp.qt) of the recommended engine oil. Then, start the engine, race it 5 or 6 times, turn it off, and then add the remainder of the engine oil. NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-13 TIP The coolant should be between the minimum and maximum le v el marks. 1. Coolant reservoir 2. Maximum le vel mark 3. Minimum le vel mark 4. Reser voir cap 3. If the coolant is at or below the minimum le vel mark, remov e pan- el E (See page 7-7.), remov e the reser v oir cap, add cool[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-14 1 2 3 4 5 6 7 8 9 10 1. Air filter element ECA10480 NOTICE ● Make sure that the air filter ele- ment is properly 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. 5. In[...]

T o clean the air filter check hose 1. Air filter check hose 2. Check hose cap 1. Check the hose on the side of the air filter case for accumulated dirt or water . 2. If dirt or water is visible, remove the hose, clean it, and then install it. EAU44734 Checking the engine idling speed 1. Idle adjusting screw a. Increasing the engine idling speed b.[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-16 1 2 3 4 5 6 7 8 9 10 EAU21631 Tires T o maximiz e the perf ormance, durabil- ity , and safe operation of your motor- cycle, note the f ollowing points regard- ing the specified tires. Tire air pressur e Th e t ir e a ir pr es s ur e s ho ul d b e check ed and, if necessary , adjusted bef ore each ride. EWA10[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-17 EWA10511 WA RN IN G 0 Never overload your vehicle. Oper- at io n o f an o ve rl oa de d ve hi cl e could cause an accident. Tire air pr essure (measured on cold tires): Up to 90 kg (198 lb): F ront: 210 kP a (30 psi) (2.1 kgf/cm 2 ) Rear : 230 kP a (33 psi) (2.3 kgf/cm 2 ) 90 kg (198 lb)[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-18 1 2 3 4 5 6 7 8 9 10 Tire information This motorcycle is equipped with tube tires. Front tir e: Size: 90/90-21M/C 54S 90/90-21M/C 54T Manuf acturer/model: METZELER/T OURANCE FRONT MICHELIN/SIRA C Rear tire: Size: 130/80-17M/C 65S 130/80-17M/C 65T Manuf acturer/model: METZELER/T OURANCE MICHELIN/SIRA C A Tire[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-19 EAU21940 Spoke wheels T o maximiz e the perf ormance, durabil- ity , and safe operation of your motor- cycle, note the f ollowing points regard- ing the specified wheels. ● T he wh ee l r i ms sh ou ld b e ch ecked for cr acks, be nd s o r wa r pa ge, a nd t he s po ke s for lo os en e[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-20 1 2 3 4 5 6 7 8 9 10 3. T o increase the clutch le ver free pla y , tur n the adjusting bolt in di- rection (a). T o decrease the clutch le ver free play , tur n the adjusting bolt in direction (b). TIP If the specified clutch lev er free pla y could be obtained as descr ibed above , skip steps 4-7. 4. Fully[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-21 EAU22390 Checking the front and r ear brake pads The front and rear brak e pads must be check ed f or wear at the inter v als spec- ified in the periodic maintenance and lubrication char t. EAU22420 Front brake pads 1. Front brake pad wear indicator groove Each front brake pad is provide[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-22 1 2 3 4 5 6 7 8 9 10 Insufficient brak e fluid may allo w air to enter the brak e system, possibly caus- ing it to become ineff ective . Bef ore riding, check that the brak e flu- id is abov e the minimum le vel mark and replenish if necessar y . A low brak e fluid lev el may indicate worn brak e pads and/or[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-23 EAU22731 Changing the brake fluid Hav e a Y amaha dealer change the brak e fluid at the intervals specified in the TIP after the periodic maintenance and lubrication char t. In addition, hav e the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the i[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-24 1 2 3 4 5 6 7 8 9 10 1. Wheel axle 2. Dr iv e chain slack adjusting bolt 3. Locknut 4. Alignment marks TIP Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same po- sition f or proper wheel alignment. 3. Tigh ten th e a xle n ut, th en the l oc k- nu ts to [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-25 EAU23023 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the inter v als specified in the periodic maintenance and lubrica- tion char t, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Ser vice the drive chain a[...]

EAU231 1 1 Checking and lubricating the thr ottle grip and cable Th e o pera tio n o f the th rott le gr ip should be checked before each ride. In addition, the cable should be lubri- cated at the intervals specified in the periodic maintenance chart. EAU23142 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operati[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23182 Checking and lubricating the brake pedal The opera tion of the brake pe dal should be check ed before each r ide , and the pedal pivot should be lubricat- ed if necessar y . Recommended lubricant: Lithium-soap-based grease EAU23202 Checking and lubricating the sidestand The operation[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-28 1 2 3 4 5 6 7 8 9 10 EAU23272 Checking the front fork The condition and operation of the front fork must be check ed as follo ws at t he i nt er va ls sp e ci fi ed i n t he periodic maintenance and lubrication char t. T o check the condition Check the inner tubes for scratches, damage and e xcessive oil lea[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-29 EAU23283 Checking the steering W or n or loose steering bear ings may cause danger . Therefore , the oper a- tion of the steer ing must be checked as follows at the inter vals specified in the periodic maintenance and lubrica- tion char t. 1. Place a stand under the engine to ra is e t h[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-30 1 2 3 4 5 6 7 8 9 10 EWA10760 WA RN IN G 0 ● Electrolyte is poisonous an d da nge rous si nce i t c ont ai ns sulfuric acid, which causes se- vere bur ns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the fol- lowing FI[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-31 ECA16520 NOTICE T o charg e a VRLA (V alve Regul ate d Lea d Acid ) batt ery , a spec ial (co n- sta nt- volt age) batt ery ch arge r is r e- qui re d. Usin g a con vent ion al b atte ry cha rge r wil l dam age the batt ery . If you do not ha ve acc ess to a con- sta nt- volt age bat ter[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-32 1 2 3 4 5 6 7 8 9 10 ECA10640 NOTICE Do not use a fuse of a higher am- perage rating than recommended to avoid causing extensive damage to the electrical system and possi- bly a fire. 3. T ur n the ke y to “ON” and tur n on the electr ical circuit in question to check if the de vice operates . 4. I f t h[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-33 EAUB1580 Replacing a headlight bulb 1. Headlight bulb cov er 1. Headlight coupler 2. Headlight bulb holder 3. Headlight bulb EWA10790 WA RN IN G 0 Headlight bulbs get very hot. There- fo re , k ee p f la mm ab le p rod uc ts away from a lit headlight bulb, and do not touch the bulb until[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-34 1 2 3 4 5 6 7 8 9 10 ECA10650 NOTICE T ake care not to damage the fol- lowing parts: ● Headlight bulb • Do not touch the glass part of the headlight bulb to keep it fr ee fr om oil, otherwise the tran sparency of the glas s, the luminosity of the bulb, and the bulb life will be ad- versely affected. Thor[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-35 EAU42652 Replacing an auxiliary light bulb 1. Auxiliary light socket 2. Auxiliary light bulb This model is equipped with two auxil- iar y lights. If an auxiliar y light bulb burns out, replace it as follo ws. 1. Remove panel G. (See page 7-7.) 2. Re m o v e t he au xi l i ary li g h t s [...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-36 1 2 3 4 5 6 7 8 9 10 T o service the rear wheel Raise the rear wheel off the g round by using a motorcycle stand or , if a mo- torcycle stand is not availab le, b y plac- ing a jac k either under each side of the frame in front of the rear wheel or un- der each side of the s wingar m. EAU24360 Front wheel EA[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-37 1. Loosen the front wheel axle pinch bolts, the wheel axle and the brak e caliper bolts. 2. Lift the front wheel off the ground according to the procedure on page 7-36. 3. R emove th e bra ke c ali pe r o n each side by remo ving the bolts. ECA11050 NOTICE Do not apply the brake after th[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-38 1 2 3 4 5 6 7 8 9 10 TIP ● If th e driv e chai n is dif ficu lt to re- mo v e, remo v e the wheel axle fi rst , and then lift the wheel upw ard eno ugh to rem ov e the driv e cha in fro m t he r ear spr oc ke t. ● The drive chain cannot be disas- sembled. 7. W hi le su pp o r ti ng t he b ra ke caliper b[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-39 TIP ● Make sure that the slot in the brak e caliper brac ket is fit ov er the retainer on the s wingar m. ● Make sure that there is enough space between the brak e pads bef ore installing the wheel. 2. Install the drive chain onto the rear sprock et. 3. Install the axle nut, and then[...]

PERIODIC MAINTENANCE AND ADJUSTMENT 7-40 1 2 3 4 5 6 7 8 9 10 EAU42131 T roubleshooting charts Starting pr oblems or poor engine performance 1. Fuel 2. Compr ession 3. Ignition 4. Battery Check the fuel lev el in the fuel tank. Operate the electric star ter . Remov e the spark plug and chec k the electrodes. Operate the electric star ter . There is[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND ADJUSTMENT 7-41 Engine overheating EWA10400 WA RN IN G 0 ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressur e, which could cause serious injury . Be sur e to wait until the engine has cooled. ● After r emovi ng the radia[...]

MOTORCYCLE CARE AND STORAGE 8-1 1 2 3 4 5 6 7 8 9 10 EAU26004 Care While the open design of a motorcycle re veals the attractiveness of the tech- nology , it also makes it more vulnera- ble . Rust and corrosion can de velop e ven if high-quality components are used. A rusty exhaust pipe ma y go un- noticed on a car , howe ver , it detracts from the[...]

1 2 3 4 5 6 7 8 9 10 MOTORCYCLE CARE AND STORAGE 8-2 ● For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as th ey w il l c au se d ul li ng or sc ra tc hi n g. S om e cl ea ni ng co mp ou nd s f or p la st ic ma y leave scratches on the wind- shield. T est the product on a small hidden part of the wind- shield[...]

MOTORCYCLE CARE AND STORAGE 8-3 1 2 3 4 5 6 7 8 9 10 8. Let the motorcycle dry completely bef ore storing or covering it. EWA11131 WA RN IN G 0 Con tami nant s o n t he brak es or tires can cause loss of contr ol. ● Make sur e that there is no oil or wax on the brakes or tires. ● If necessary , clean the brake discs and brake linings with a reg[...]

1 2 3 4 5 6 7 8 9 10 MOTORCYCLE CARE AND STORAGE 8-4 Long-term Bef ore storing your motorcycle f or se v- eral months: 1. Follo w all the instr uctions in the “Care” section of this chapter . 2. Fill up the fuel tank and add fuel stabilizer (if a vailab le) to prev ent the fuel tank from rusting and the fuel from deteriorating. 3. P erform the [...]

SPECIFICA TIONS 9-1 1 2 3 4 5 6 7 8 9 10 Engine oil: T ype: SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade: API ser vice SE, SF , SG type or higher Engine oil quantity: Without oil filter element replacement: 2.50 L (2.64 US qt) (2.19 Imp.qt) With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.q[...]

1 2 3 4 5 6 7 8 9 10 SPECIFICA TIONS 9-2 Operation: Left foot operation Gear ratio: 1 st : 30/12 (2.500) 2 nd : 26/16 (1.625) 3 rd : 23/20 (1.150) 4 th : 20/22 (0.909) 5 th : 20/26 (0.769) Chassis: F rame type: Diamond Caster angle: 28° T rail: 113.0 mm (4.44 in) Front tire: T ype: With tube Size: 90/90-21M/C 54S, 90/90-21M/C 54T Manuf acturer/mod[...]

SPECIFICA TIONS 9-3 1 2 3 4 5 6 7 8 9 10 Rear suspension: T ype: Swingarm (link suspension) Spring/damper type: Coil spr ing/gas-oil damper , spring preload adjustable Wheel travel: 200 mm (7.87 in) Electrical system: Ignition system: T ransistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: GT9B-4 V oltage, capacity: 12[...]

EAU26351 Identification numbers Record the key identification number , ve hi cl e i de nt i fi ca ti on n um be r a nd model label information in the spaces provided below for assistance when ordering spare parts from a Y amaha dealer or for reference in case the ve- hicle is stolen. KEY IDENTIFICA TION NUMBER: VE HI CLE I DE NT IFI CA TI ON NU MB [...]

EAU26570 Motorcycle noise regulation (for Australia) T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Owners are warned that the law may prohibit: a. The removal or rendering inoperati- ve by any person other than for pur- poses of maintenance, repair or replacement, of any device or ele- ment of design incorporated into any new vehicle for the pur[...]

1 2 3 4 5 6 7 8 9 10 INDEX A Aftermar k et P ar ts, Accessories, and Modifications ...................................2-4 Aftermar k et Tires and Rims ...............2-4 Air filter element, cleaning the check hose ..............................................7-14 Air filter element, replacing ..............7-14 A uxiliar y light bulb , replacing..[...]

Dimmer switch ................................4-9 Engine stop switch ..........................4-9 Hazard switch ...............................4-10 Horn switch .....................................4-9 Pass switch .....................................4-9 Start switch .....................................4-9 T urn signal switch .....................[...]

1 2 3 4 5 6 7 8 9 10 INDEX Specifications .....................................9-1 Spoke wheels ...................................7-19 Star t switch ........................................4-9 Star ting the engine .............................6-1 Steering, checking............................7-29 Steering lock .....................................[...]

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03 ingles -australia 26/2/10 10:49 Página 96[...]

03 ingles -australia 26/2/10 10:49 Página 96[...]

03 ingles -australia 26/2/10 10:49 Página 96[...]

MBK Industrie Z.I. de Rouvroy 02100 Saint Quentin Société Anonyme au capital de 45 000 000 e R.C St-Quentin B 329 035 422 PRINTED IN FRANCE 2012-03 (E)[...]