Yamaha XTZ690 2020 Adventure Motorcycle Manuals

Manuals and User Guides for Yamaha XTZ690 2020 Adventure Motorcycle. We have 1 Yamaha XTZ690 2020 Adventure Motorcycle manual available for free PDF download: Service Manual

Yamaha XTZ690 2020 Service Manual

Yamaha XTZ690 2020 Service Manual (472 pages)

Brand: Yamaha | Category: Motorcycle | Size: 17 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
  - Special Tools
    16
Specifications

23
- General Specifications
  24
- Engine Specifications
  25
- Chassis Specifications
  30
- Electrical Specifications
  33
- Tightening Torques
  35
  - Engine Tightening Torques
    35
  - Chassis Tightening Torques
    36
- Cable Routing
  38
Periodic Checks and Adjustments

63
Chassis

97
- General Chassis (1)
  
  101
- General Chassis (2)
  
  101
  - Removing the Side Covers
    102
  - Removing the Tail Cover
    102
  - REMOVING the ECU (Engine Control Unit)
    102
  - INSTALLING the ECU (Engine Control Unit)
    102
  - Installing the Tail Cover
    102
  - Installing the Side Covers
    102
- General Chassis (3)
  
  103
  - Removing the Air Scoops
    105
  - Removing the Air Ducts
    105
  - Removing the Fuel Tank Side Covers
    105
  - Installing the Fuel Tank Side Covers
    105
  - Installing the Air Ducts
    105
  - Installing the Air Scoops
    106
- General Chassis (4)
  
  107
  - Removing the Meter Assembly
    109
  - Installing the Windshields
    109
  - Installing the Meter Assembly
    109
- Front Wheel
  
  110
  - Removing the Front Wheel
    112
  - Disassembling the Front Wheel
    112
  - Checking the Front Wheel
    112
  - Maintenance of the Front Wheel Sensor and Sensor Rotor
    113
  - Assembling the Front Wheel
    114
  - Adjusting the Front Wheel Static Balance
    114
  - Installing the Front Wheel
    114
- Rear Wheel
  
  117
- Front Brake
  
  124
- Rear Brake
  
  134
  - Introduction
    139
  - Checking the Rear Brake Disc
    139
  - Replacing the Rear Brake Pads
    139
  - Removing the Rear Brake Caliper
    140
  - Checking the Rear Brake Caliper
    140
  - Installing the Rear Brake Caliper
    140
  - Removing the Rear Brake Master Cylinder
    141
  - Checking the Rear Brake Master Cylinder
    141
  - Assembling the Rear Brake Master Cylinder
    141
  - Installing the Rear Brake Master Cylinder
    142
  - Assembling the Brake Pedal
    142
- Abs (Anti-Lock Brake System)
  
  143
- Handlebar
  
  151
  - Removing the Handlebar
    153
  - Checking the Handlebar
    153
  - Installing the Handlebar
    153
- Front Fork
  
  157
  - Removing the Front Fork Legs
    160
  - Disassembling the Front Fork Legs
    160
  - Checking the Front Fork Legs
    161
  - Assembling the Front Fork Legs
    162
  - Installing the Front Fork Legs
    165
- Steering Head
  
  167
  - Removing the Lower Bracket
    169
  - Checking the Steering Head
    169
  - Installing the Steering Head
    170
- Rear Shock Absorber Assembly
  
  171
- Swingarm
  
  174
  - Removing the Swingarm
    176
  - Checking the Swingarm
    176
  - Installing the Swingarm
    177
- Chain Drive
  
  179
  - Removing the Drive Sprocket
    181
  - Checking the Drive Chain
    181
  - Checking the Drive Sprocket
    182
  - Checking the Rear Wheel Sprocket
    182
  - Checking the Rear Wheel Drive Hub
    182
  - Installing the Drive Sprocket
    182
  - Installing the Drive Chain
    183
Engine

185
- Engine Inspection
  
  188
  - Measure the Compression Pressure
    188
- Engine Removal
  
  190
  - Removing the Engine
    195
  - Installing the Engine
    195
  - Installing the Exhaust Pipe and Muffler
    196
- Camshafts
  
  197
  - Removing the Ignition Coils
    200
  - Removing the Camshafts
    200
  - Checking the Camshafts
    201
  - Checking the Camshaft Sprockets
    202
  - Checking the Timing Chain Tensioner
    202
  - Checking the Decompression System
    202
  - Installing the Camshafts
    203
  - Installing the Cylinder Head Cover
    206
- Cylinder Head
  
  208
  - Removing the Cylinder Head
    211
  - Checking the Timing Chain Guides
    211
  - Checking the Cylinder Head
    211
  - Installing the Cylinder Head
    212
- Valves and Valve Springs
  
  214
  - Removing the Valves
    215
  - Checking the Valves and Valve Guides
    215
  - Checking the Valve Seats
    217
  - Checking the Valve Springs
    218
  - Checking the Valve Lifters
    218
  - Installing the Valves
    218
- Generator and Starter Clutch
  
  220
  - Removing the Generator
    222
  - Removing the Starter Clutch
    222
  - Checking the Starter Clutch
    222
  - Checking the Torque Limiter
    223
  - Installing the Starter Clutch
    223
  - Installing the Generator
    223
- Electric Starter
  
  225
  - Checking the Starter Motor
    227
  - Assembling the Starter Motor
    227
  - Installing the Starter Motor
    228
- Clutch
  
  229
  - Removing the Clutch
    233
  - Checking the Friction Plates
    233
  - Checking the Clutch Plates
    234
  - Checking the Clutch Springs
    234
  - Checking the Clutch Housing
    234
  - Checking the Clutch Boss
    234
  - Checking the Pressure Plate
    234
  - Checking the Primary Drive Gear
    234
  - Checking the Primary Driven Gear
    234
  - Checking the Pull Lever Shaft and Pull Rod
    235
  - Installing the Clutch
    235
- Shift Shaft
  
  238
  - Checking the Shift Shaft
    240
  - Checking the Stopper Lever
    240
  - Installing the Shift Shaft
    240
- Oil Pump
  
  241
  - Checking the Sprocket and Chain
    243
  - Checking the Oil Pump
    243
  - Checking the Relief Valve
    243
  - Assembling the Oil Pump
    243
  - Installing the Oil Pump
    244
- Oil Pan
  
  245
  - Removing the Oil Pan
    246
  - Checking the Oil Strainer
    246
  - Installing the Oil Pan
    246
- Crankcase
  
  247
  - Disassembling the Crankcase
    249
  - Checking the Crankcase
    249
  - Assembling the Crankcase
    249
  - Installing the Oil Pressure Switch
    251
- Connecting Rods and Pistons
  
  254
  - Removing the Connecting Rods and Pistons
    254
  - Checking the Cylinder and Piston
    254
  - Checking the Piston Rings
    255
  - Checking the Piston Pin
    256
  - Checking the Connecting Rods
    256
  - Installing the Connecting Rod and Piston
    259
- Crankshaft and Balancer Shaft
  
  263
- Transmission
  
  269
  - Removing the Transmission
    273
  - Checking the Shift Forks
    273
  - Checking the Shift Drum Assembly
    273
  - Checking the Transmission
    274
  - Assembling the Main Axle and Drive Axle
    274
  - Installing the Transmission
    275
Cooling System

277
- Cooling System Diagrams
  
  278
- Radiator
  
  279
  - Checking the Radiator
    281
  - Installing the Radiator
    281
- Oil Cooler
  
  282
  - Checking the Oil Cooler
    284
  - Checking the Water Jacket Joint
    284
  - Checking the Thermostat
    284
  - Installing the Oil Cooler
    284
  - Installing the Thermostat
    285
- Thermostat
  
  286
- Water Pump
  
  287
  - Disassembling the Water Pump
    289
  - Checking the Water Pump
    289
  - Assembling the Water Pump
    289
  - Installing the Clutch Cover
    291
Fuel System

293
- Fuel Tank
  
  295
  - Checking the Cylinder Head Breather Hose
    296
  - Checking the Fuel Pump Body
    296
  - Checking the Rollover Valve
    296
  - Installing the Canister
    296
  - Removing the Fuel Pump
    296
  - Removing the Fuel Tank
    296
  - Installing the Fuel Pump
    297
  - Installing the Fuel Tank
    297
- Throttle Bodies
  
  298
  - Removing the Throttle Bodies
    301
  - Checking the Injectors (before Removing)
    301
  - Removing the Injectors
    301
  - Checking the Injectors
    301
  - Checking and Cleaning the Throttle Bodies
    301
  - Checking the Throttle Body Joints
    304
  - Adjusting the Throttle Position Sensor
    304
  - Installing the Fuel Injectors
    304
  - Checking the Injector Pressure
    305
  - Checking the Fuel Pressure
    305
  - Installing the Throttle Body Joints
    306
  - Installing the Air Filter Case Joints
    306
  - Installing the Throttle Bodies
    307
Electrical System

309
- Ignition System
  
  312
  - Circuit Diagram
    312
  - Engine Stopping Due to Sidestand Operation
    314
  - Troubleshooting
    315
- Electric Starting System
  
  318
  - Circuit Diagram
    318
  - Starting Circuit Cut-Off System Operation
    320
  - Troubleshooting
    321
- Charging System
  
  323
  - Circuit Diagram
    323
  - Troubleshooting
    324
- Lighting System
  
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
- Signaling System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Cooling System
  
  338
  - Circuit Diagram
    338
  - Troubleshooting
    340
- Fuel Injection System
  
  342
  - Circuit Diagram
    342
  - Ecu Self-Diagnostic Function
    344
  - Troubleshooting Method
    344
  - Yamaha Diagnostic Tool
    345
  - Troubleshooting Details (Fault Code)
    345
- Appendix
  
  453
  - Self-Diagnostic Function and Diagnostic Code Table
    454
    
    Self-Diagnostic Function Table (for Fuel Injection System)
    454
    
    Self-Diagnostic Function Table (for Immobilizer System)
    460
    
    Diagnostic Code: Sensor Operation Table
    461
    
    Diagnostic Code: Actuator Operation Table
    463
  - Event Code Table
    465

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