Yamaha XSR MTM690 2016 Manuals

Yamaha XSR MTM690 2016 Manuals

Manuals and User Guides for Yamaha XSR MTM690 2016. We have 1 Yamaha XSR MTM690 2016 manual available for free PDF download: Service Manual

Yamaha XSR MTM690 2016 Service Manual

Yamaha XSR MTM690 2016 Service Manual (568 pages)

Brand: Yamaha | Category: Motorcycle | Size: 24.38 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Multi-Function Meter Unit
  11
- Gaskets, Oil Seals and O-Rings
  16
- Lock Washers/Plates and Cotter Pins
  16
- Replacement Parts
  16
- Preparation for Removal and Disassembly
  16
- Important Information
  16
- Bearings and Oil Seals
  17
- Circlips
  17
- Rubber Parts
  17
- Basic Service Information
  18
- Quick Fasteners
  18
- Electrical System
  19
- Special Tools
  23
Specifications

29
- General Specifications
  30
- Engine Specifications
  31
- Chassis Specifications
  37
- Electrical Specifications
  40
- General Tightening Torque Specifications
  43
- Tightening Torques
  43
- Engine Tightening Torques
  44
- Chassis Tightening Torques
  49
- Engine
  53
- Lubrication Points and Lubricant Types
  53
- Chassis
  54
- Engine Oil Lubrication Chart
  56
- Lubrication System Chart and Diagrams
  56
- Lubrication Diagrams
  58
- Cooling System Diagrams
  70
- Cable Routing
  72
Periodic Checks and Adjustments

103
- General Maintenance and Lubrication Chart
  106
- Introduction
  106
- Periodic Maintenance
  106
- Periodic Maintenance Chart for the Emission Control System
  106
- Checking the Fuel Line
  109
- Checking the Spark Plugs
  109
- Adjusting the Valve Clearance
  110
- Checking the Engine Idling Speed
  113
- Synchronizing the Throttle Bodies
  113
- Checking the Canister
  115
- Checking the Throttle Body Joints
  115
- Replacing the Air Filter Element and Cleaning the
  116
- Adjusting the Clutch Lever Free Play
  117
- Adjusting the Front Disc Brake
  117
- Checking the Brake Operation
  117
- Adjusting the Rear Disc Brake
  118
- Checking the Front Brake Pads
  118
- Bleeding the Hydraulic Brake System (Abs)
  119
- Checking the Brake Hoses
  119
- Checking the Rear Brake Pads
  119
- Checking the Brake Fluid Level
  120
- Checking the Tires
  121
- Checking the Wheels
  121
- Adjusting the Drive Chain Slack
  122
- Checking the Swingarm Operation
  122
- Checking the Wheel Bearings
  122
- Lubricating the Swingarm Pivot
  122
- Checking and Adjusting the Steering Head
  124
- Checking the Chassis Fasteners
  124
- Lubricating the Drive Chain
  124
- Lubricating the Steering Head
  124
- Adjusting the Rear Shock Absorber Assembly
  125
- Checking the Front Fork
  125
- Checking the Rear Shock Absorber Assembly
  125
- Checking the Sidestand
  125
- Checking the Sidestand Switch
  125
- Lubricating the Brake Lever
  125
- Lubricating the Clutch Lever
  125
- Lubricating the Pedal
  125
- Lubricating the Sidestand
  125
- Changing the Engine Oil
  126
- Checking the Connecting Arm and Relay Arm
  126
- Checking the Engine Oil Level
  126
- Checking the Coolant Level
  128
- Measuring the Engine Oil Pressure
  128
- Changing the Coolant
  129
- Checking the Cooling System
  129
- Adjusting the Rear Brake Light Switch
  131
- Checking and Lubricating the Cables
  131
- Checking the Front Brake Light Switch
  131
- Checking the Throttle Grip Operation
  132
- Checking and Charging the Battery
  133
- Checking the Fuses
  133
- Replacing the Headlight Bulb
  133
- Adjusting the Headlight Beam
  134
- Replacing the License Plate Light Bulb
  134
Chassis

137
- General Chassis (1)
  141
- Installing the Seat
  141
- Installing the Yamaha Diagnostic Tool Coupler
  141
- General Chassis (2)
  142
- Installing the Headlight Assembly
  143
- General Chassis (3)
  144
- General Chassis (4)
  145
- Installing the Fuel Tank Covers
  145
- Installing the Air Duct
  147
- General Chassis (5)
  148
- INSTALLING the ECU (Engine Control Unit)
  150
- Installing the Electrical Components Trays
  150
- REMOVING the ECU (Engine Control Unit)
  150
- Front Wheel
  151
- Checking the Front Wheel
  153
- Disassembling the Front Wheel
  153
- Removing the Front Wheel
  153
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  154
- Adjusting the Front Wheel Static Balance
  155
- Assembling the Front Wheel
  155
- Installing the Front Wheel (Disc Brake)
  156
- Rear Wheel
  159
- Checking the Rear Wheel
  163
- Checking the Rear Wheel Drive Hub
  163
- Disassembling the Rear Wheel
  163
- Removing the Rear Wheel (Disc Brake)
  163
- Checking and Replacing the Rear Wheel Sprocket
  164
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  164
- Adjusting the Rear Wheel Static Balance
  165
- Assembling the Rear Wheel
  165
- Installing the Rear Wheel (Rear Brake Disc)
  165
- Front Brake
  168
- Checking the Front Brake Discs
  174
- Introduction
  174
- Replacing the Front Brake Pads
  175
- Removing the Front Brake Calipers
  176
- Checking the Front Brake Calipers
  177
- Disassembling the Front Brake Calipers
  177
- Assembling the Front Brake Calipers
  178
- Installing the Front Brake Calipers
  178
- Assembling the Front Brake Master Cylinder
  179
- Checking the Front Brake Master Cylinder
  179
- Removing the Front Brake Master Cylinder
  179
- Installing the Front Brake Master Cylinder
  180
- Rear Brake
  182
- Checking the Rear Brake Disc
  188
- Introduction
  188
- Replacing the Rear Brake Pads
  188
- Checking the Rear Brake Caliper
  190
- Disassembling the Rear Brake Caliper
  190
- Removing the Rear Brake Caliper
  190
- Assembling the Rear Brake Caliper
  191
- Installing the Rear Brake Caliper
  191
- Checking the Rear Brake Master Cylinder
  192
- Removing the Rear Brake Master Cylinder
  192
- Assembling the Rear Brake Master Cylinder
  193
- Installing the Rear Brake Master Cylinder
  193
- Abs (Anti-Lock Brake System)
  195
- Checking the Hydraulic Unit Assembly
  197
- Installing the Hydraulic Unit Assembly
  197
- Removing the Hydraulic Unit Assembly
  197
- Hydraulic Unit Operation Tests
  199
- Checking the Abs Warning Light
  203
- Handlebar
  204
- Checking the Handlebar
  206
- Installing the Handlebar
  206
- Removing the Handlebar
  206
- Front Fork
  209
- Disassembling the Front Fork Legs
  213
- Removing the Front Fork Legs
  213
- Assembling the Front Fork Legs
  214
- Checking the Front Fork Legs
  214
- Installing the Front Fork Legs
  217
- Steering Head
  219
- Checking the Steering Head
  221
- Installing the Steering Head
  221
- Removing the Lower Bracket
  221
- Rear Shock Absorber Assembly
  223
- Checking the Rear Shock Absorber Assembly
  225
- Checking the Relay Arm
  225
- Disposing of a Rear Shock Absorber
  225
- Handling the Rear Shock Absorber
  225
- Installing the Relay Arm
  225
- Removing the Rear Shock Absorber Assembly
  225
- Installing the Rear Shock Absorber Assembly
  226
- Swingarm
  227
- Checking the Connecting Arm
  229
- Checking the Swingarm
  229
- Removing the Swingarm
  229
- Installing the Connecting Arm
  230
- Installing the Swingarm
  230
- Chain Drive
  232
- Checking the Drive Chain
  234
- Removing the Drive Chain
  234
- Removing the Drive Sprocket
  234
- Checking the Drive Sprocket
  236
- Checking the Rear Wheel Drive Hub
  236
- Checking the Rear Wheel Sprocket
  236
- Installing the Drive Chain
  236
- Installing the Drive Sprocket
  236
Engine

239
- Engine Inspection
  242
- Measure the Compression Pressure
  242
- Adjusting the Exhaust Gas Volume
  243
- Checking the Cylinder Head Breather Hose
  243
- Engine Removal
  244
- Installing the Engine
  249
- Removing the Engine
  249
- Camshafts
  252
- Removing the Camshafts
  256
- Checking the Camshafts
  257
- Checking the Camshaft Sprockets
  258
- Checking the Decompression System
  259
- Checking the Timing Chain Tensioner
  259
- Installing the Camshafts
  259
- Installing the Cylinder Head Cover
  263
- Cylinder Head
  264
- Checking the Cylinder Head
  267
- Checking the Timing Chain Guides
  267
- Removing the Cylinder Head
  267
- Installing the Cylinder Head
  268
- Checking the Valves and Valve Guides
  270
- Removing the Valves
  270
- Valves and Valve Springs
  270
- Checking the Valve Seats
  272
- Checking the Valve Springs
  273
- Checking the Valve Lifters
  274
- Installing the Valves
  274
- Generator and Starter Clutch
  277
- Checking the Starter Clutch
  280
- Removing the Generator
  280
- Removing the Starter Clutch
  280
- Checking the Torque Limiter
  281
- Installing the Generator
  281
- Installing the Starter Clutch
  281
- Electric Starter
  283
- Checking the Starter Motor
  285
- Assembling the Starter Motor
  286
- Installing the Starter Motor
  286
- Clutch
  287
- Removing the Clutch
  291
- Checking the Clutch Plates
  292
- Checking the Clutch Springs
  292
- Checking the Friction Plates
  292
- Checking the Clutch Boss
  293
- Checking the Clutch Housing
  293
- Checking the Pressure Plate
  293
- Checking the Primary Drive Gear
  293
- Checking the Primary Driven Gear
  293
- Checking the Pull Lever Shaft and Pull Rod
  293
- Installing the Clutch
  294
- Shift Shaft
  297
- Checking the Shift Shaft
  298
- Checking the Stopper Lever
  298
- Installing the Shift Shaft
  298
- Oil Pump
  299
- Assembling the Oil Pump
  301
- Checking the Oil Pump
  301
- Checking the Relief Valve
  301
- Checking the Sprocket and Chain
  301
- Installing the Oil Pump
  302
- Oil Pan
  303
- Checking the Oil Strainer
  304
- Installing the Oil Pan
  304
- Removing the Oil Pan
  304
- Crankcase
  305
- Assembling the Crankcase
  307
- Checking the Crankcase
  307
- Disassembling the Crankcase
  307
- Installing the Oil Pressure Switch
  309
- Connecting Rods and Pistons
  311
- Checking the Cylinder and Piston
  313
- Removing the Connecting Rods and Pistons
  313
- Checking the Piston Rings
  314
- Checking the Piston Pin
  315
- Checking the Connecting Rods
  316
- Installing the Connecting Rod and Piston
  318
- Crankshaft and Balancer Shaft
  323
- Checking the Balancer Shaft Assembly
  324
- Removing the Balancer Shaft Journal Bearings
  324
- Removing the Crankshaft Journal Bearings
  324
- Checking the Crankshaft
  326
- Installing the Balancer Shaft Assembly
  328
- Installing the Crankshaft
  328
- Transmission
  329
- Checking the Shift Drum Assembly
  334
- Checking the Shift Forks
  334
- Removing the Transmission
  334
- Assembling the Main Axle and Drive Axle
  335
- Checking the Transmission
  335
- Installing the Transmission
  336
Cooling System

339
- Radiator
  340
- Checking the Radiator
  342
- Installing the Radiator Side Cover Brackets and Radiator Side Covers
  342
- Installing the Radiator
  343
- Oil Cooler
  344
- Checking the Oil Cooler
  345
- Checking the Water Jacket Joint
  345
- Installing the Oil Cooler
  345
- Thermostat
  346
- Checking the Thermostat
  347
- Installing the Thermostat
  347
- Water Pump
  348
- Assembling the Water Pump
  350
- Checking the Water Pump
  350
- Disassembling the Water Pump
  350
- Installing the Clutch Cover
  352
Fuel System

353
- Fuel Tank
  354
- Checking the Fuel Pump Body
  357
- Installing the Canister
  357
- Installing the Fuel Pump
  357
- Removing the Fuel Pump
  357
- Removing the Fuel Tank
  357
- Installing the Dampers
  358
- Installing the Fuel Tank
  358
- Installing the Fuel Tank Bracket
  358
- Throttle Bodies
  360
- Checking the Injectors
  363
- Checking the Injectors (before Removing)
  363
- Checking the Throttle Bodies
  363
- Cleaning the Isc (Idle Speed Control) Valve
  363
- Removing the Injectors
  363
- Checking the Throttle Body Joints
  365
- Adjusting the Throttle Position Sensor
  366
- Installing the Fuel Injectors
  366
- Checking the Fuel Pressure
  367
- Checking the Injector Pressure
  367
- Installing the Air Filter Case
  368
- Installing the Throttle Body Joints
  368
Electrical System

369
- Circuit Diagram
  372
- Ignition System
  372
- Engine Stopping Due to Sidestand Operation
  374
- Troubleshooting
  375
- Circuit Diagram
  378
- Electric Starting System
  378
- Starting Circuit Cut-Off System Operation
  380
- Troubleshooting
  381
- Charging System
  384
- Circuit Diagram
  384
- Troubleshooting
  386
- Circuit Diagram
  388
- Lighting System
  388
- Troubleshooting
  390
- Circuit Diagram
  392
- Signaling System
  392
- Troubleshooting
  394
- Circuit Diagram
  400
- Cooling System
  400
- Troubleshooting
  402
- Circuit Diagram
  404
- Fuel Injection System
  404
- Ecu Self-Diagnostic Function
  406
- Troubleshooting Method
  406
- Yamaha Diagnostic Tool
  407
- Troubleshooting Details (Fault Code)
  409
Troubleshooting

543
- General Information
  544
- Incorrect Engine Idling Speed
  544
- Starting Failure
  544
- Troubleshooting
  544
- Faulty Clutch
  545
- Faulty Gear Shifting
  545
- Jumps out of Gear
  545
- Overheating
  545
- Poor Medium-And-High-Speed Performance
  545
- Shift Pedal Does Not Move
  545
- Faulty Front Fork Legs
  546
- Overcooling
  546
- Poor Braking Performance
  546
- Unstable Handling
  546
- Faulty Lighting or Signaling System
  547
- Troubleshooting at the Abs Warning Light
  547
- Self-Diagnostic Function and Diagnostic Code Table
  548
- Self-Diagnostic Function Table (for Fuel Injection System)
  548
- Self-Diagnostic Function Table (for Immobilizer System)
  554
- Diagnostic Code: Sensor Operation Table
  555
- Diagnostic Code: Actuator Operation Table
  557
- Event Code Table
  559

Advertisement

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals