Yamaha XTZ690DP Manuals

Manuals and User Guides for Yamaha XTZ690DP. We have 2 Yamaha XTZ690DP manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha XTZ690DP Service Manual

Yamaha XTZ690DP Service Manual (638 pages)

Brand: Yamaha | Category: Motorcycle | Size: 30 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Display
  11
- Special Tools
  20
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  33
- Electrical Specifications
  36
- Engine Tightening Torques
  38
- Tightening Torques
  38
- Chassis Tightening Torques
  39
- Cable Routing
  42
Periodic Checks and Adjustments

79
- General Maintenance and Lubrication Chart
  82
- Introduction
  82
- Periodic Maintenance
  82
- Periodic Maintenance Chart for the Emission Control System
  82
- Checking the Fuel Line
  85
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  85
- Checking the Spark Plugs
  86
- Adjusting the Valve Clearance
  87
- Checking the Engine Idling Speed
  90
- Synchronizing the Throttle Bodies
  90
- Checking the Canister
  92
- Checking the Exhaust System
  92
- Adjusting the Exhaust Gas Volume
  93
- Replacing the Air Filter Element and Cleaning the Check Hose
  93
- Adjusting the Clutch Lever Free Play
  94
- Adjusting the Front Disc Brake
  94
- Checking the Brake Operation
  94
- Adjusting the Rear Disc Brake
  95
- Checking the Front Brake Pads
  95
- Checking the Rear Brake Pads
  95
- Bleeding the Hydraulic Brake System (Abs)
  96
- Checking the Brake Hoses
  96
- Checking and Tightening the Spokes
  97
- Checking the Brake Fluid Level
  97
- Checking the Wheels
  97
- Checking the Tires
  98
- Adjusting the Drive Chain Slack
  99
- Checking the Swingarm Operation
  99
- Checking the Wheel Bearings
  99
- Lubricating the Swingarm Pivot
  99
- Checking and Adjusting the Steering Head
  100
- Lubricating the Drive Chain
  100
- Lubricating the Steering Head
  101
- Adjusting the Front Fork Legs
  102
- Checking the Chassis Fasteners
  102
- Checking the Front Fork
  102
- Checking the Sidestand
  102
- Checking the Sidestand Switch
  102
- Checking the Steering Damper
  102
- Lubricating the Brake Lever
  102
- Lubricating the Clutch Lever
  102
- Lubricating the Pedals
  102
- Lubricating the Sidestand
  102
- Adjusting the Rear Shock Absorber Assembly
  104
- Checking the Rear Shock Absorber Assembly
  104
- Changing the Engine Oil
  106
- Checking the Connecting Arms and Relay Arm
  106
- Checking the Engine Oil Level
  106
- Measuring the Engine Oil Pressure
  107
- Checking the Coolant Level
  108
- Changing the Coolant
  109
- Checking the Cooling System
  109
- Adjusting the Rear Brake Light Switch
  111
- Checking and Lubricating the Cables
  111
- Checking the Front Brake Light Switch
  111
- Checking the Throttle Grip Operation
  112
- Adjusting the Headlight Beams
  113
- Checking and Charging the Battery
  113
- Checking the Fuses
  113
- Replacing the License Plate Light Bulb
  113
Chassis

115
- General Chassis (1)
  119
- General Chassis (2)
  119
- INSTALLING the ECU (Engine Control Unit)
  120
- Installing the Side Covers
  120
- Installing the Tail Cover
  120
- REMOVING the ECU (Engine Control Unit)
  120
- Removing the Side Covers
  120
- Removing the Tail Cover
  120
- General Chassis (3)
  121
- General Chassis (4)
  123
- Installing the Front Side Covers
  123
- Removing the Front Side Covers
  123
- General Chassis (5)
  126
- Installing the Lower Side Cover Assemblies
  126
- Installing the Side Cover Inner Panels
  126
- Removing the Lower Side Cover Assemblies
  126
- Removing the Side Cover Inner Panels
  126
- General Chassis (6)
  129
- General Chassis (7)
  130
- Removing the Windshield Inner Panel (Left)
  130
- Removing the Windshield Inner Panel (Right)
  130
- Front Wheel
  133
- Checking the Front Wheel
  135
- Disassembling the Front Wheel
  135
- Removing the Front Wheel
  135
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  136
- Adjusting the Front Wheel Static Balance
  137
- Assembling the Front Wheel
  137
- Installing the Front Wheel
  137
- Rear Wheel
  140
- Checking and Replacing the Rear Wheel Sprocket
  143
- Checking the Rear Wheel
  143
- Checking the Rear Wheel Drive Hub
  143
- Disassembling the Rear Wheel
  143
- Removing the Rear Wheel
  143
- Assembling the Rear Wheel
  144
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  144
- Adjusting the Rear Wheel Static Balance
  145
- Installing the Rear Wheel
  145
- Front Brake
  148
- Checking the Front Brake Discs
  153
- Introduction
  153
- Replacing the Front Brake Pads
  153
- Disassembling the Front Brake Calipers
  154
- Removing the Front Brake Calipers
  154
- Assembling the Front Brake Calipers
  155
- Checking the Front Brake Calipers
  155
- Installing the Front Brake Calipers
  155
- Removing the Front Brake Master Cylinder
  156
- Assembling the Front Brake Master Cylinder
  157
- Checking the Front Brake Master Cylinder
  157
- Installing the Front Brake Master Cylinder
  157
- Rear Brake
  159
- Checking the Rear Brake Disc
  166
- Introduction
  166
- Replacing the Rear Brake Pads
  166
- Checking the Rear Brake Caliper
  167
- Disassembling the Rear Brake Caliper
  167
- Removing the Rear Brake Caliper
  167
- Assembling the Rear Brake Caliper
  168
- Installing the Rear Brake Caliper
  168
- Assembling the Rear Brake Master Cylinder
  169
- Checking the Rear Brake Master Cylinder
  169
- Installing the Rear Brake Master Cylinder
  169
- Removing the Rear Brake Master Cylinder
  169
- Assembling the Brake Pedal
  170
- Abs (Anti-Lock Brake System)
  172
- Checking the Hydraulic Unit Assembly
  173
- Installing the Hydraulic Unit Assembly
  173
- Removing the Hydraulic Unit Assembly
  173
- Hydraulic Unit Operation Tests
  175
- Checking the Abs Warning Light
  178
- Handlebar
  179
- Checking the Handlebar
  181
- Installing the Handlebar
  181
- Removing the Handlebar
  181
- Front Fork
  185
- Disassembling the Front Fork Legs
  188
- Removing the Front Fork Legs
  188
- Checking the Front Fork Legs
  189
- Assembling the Front Fork Legs
  190
- Installing the Front Fork Legs
  194
- Steering Head
  196
- Checking the Steering Damper
  199
- Checking the Steering Head
  199
- Removing the Lower Bracket
  199
- Installing the Steering Head
  200
- Rear Shock Absorber Assembly
  201
- Checking the Connecting Arms and Relay Arm
  202
- Checking the Rear Shock Absorber Assembly
  202
- Disposing of a Rear Shock Absorber
  202
- Handling the Rear Shock Absorber
  202
- Installing the Rear Shock Absorber Assembly
  202
- Removing the Rear Shock Absorber Assembly
  202
- Installing the Relay Arm
  203
- Swingarm
  204
- Checking the Swingarm
  206
- Removing the Swingarm
  206
- Installing the Swingarm
  207
- Chain Drive
  209
- Checking the Drive Chain
  211
- Removing the Drive Sprocket
  211
- Checking the Drive Sprocket
  212
- Checking the Rear Wheel Drive Hub
  212
- Checking the Rear Wheel Sprocket
  212
- Installing the Drive Sprocket
  212
- Installing the Drive Chain
  213
Engine

215
- Engine Oil Lubrication Chart
  218
- Lubrication System Chart and Diagrams
  218
- Lubrication Diagrams
  219
- Engine Inspection
  225
- Measure the Compression Pressure
  225
- Engine Removal
  228
- Installing the Engine
  237
- Removing the Engine
  237
- Installing the Exhaust Pipe and Muffler
  238
- Camshafts
  240
- Removing the Camshafts
  243
- Removing the Ignition Coils
  243
- Checking the Camshafts
  244
- Checking the Cylinder Head Breather Hose
  244
- Checking the Camshaft Sprockets
  245
- Checking the Decompression System
  245
- Checking the Timing Chain Tensioner
  245
- Installing the Camshafts
  246
- Installing the Cylinder Head Cover
  249
- Cylinder Head
  251
- Checking the Cylinder Head
  254
- Checking the Timing Chain Guides
  254
- Installing the Cylinder Head
  254
- Removing the Cylinder Head
  254
- Valves and Valve Springs
  256
- Checking the Valves and Valve Guides
  257
- Removing the Valves
  257
- Checking the Valve Seats
  259
- Checking the Valve Lifters
  260
- Checking the Valve Springs
  260
- Installing the Valves
  260
- Generator and Starter Clutch
  262
- Checking the Starter Clutch
  264
- Removing the Generator
  264
- Removing the Starter Clutch
  264
- Checking the Torque Limiter
  265
- Installing the Generator
  265
- Installing the Starter Clutch
  265
- Electric Starter
  267
- Assembling the Starter Motor
  269
- Checking the Starter Motor
  269
- Installing the Starter Motor
  270
- Clutch
  271
- Checking the Friction Plates
  275
- Removing the Clutch
  275
- Checking the Clutch Boss
  276
- Checking the Clutch Housing
  276
- Checking the Clutch Plates
  276
- Checking the Clutch Springs
  276
- Checking the Pressure Plate
  276
- Checking the Primary Drive Gear
  276
- Checking the Primary Driven Gear
  276
- Checking the Pull Lever Shaft and Pull Rod
  277
- Installing the Clutch
  277
- Shift Shaft
  280
- Checking the Shift Shaft
  283
- Checking the Stopper Lever
  283
- Installing the Shift Shaft
  283
- Oil Pump
  284
- Assembling the Oil Pump
  286
- Checking the Oil Pump
  286
- Checking the Relief Valve
  286
- Checking the Sprocket and Chain
  286
- Installing the Oil Pump
  286
- Oil Pan
  288
- Checking the Oil Strainer
  289
- Installing the Oil Pan
  289
- Removing the Oil Pan
  289
- Crankcase
  290
- Assembling the Crankcase
  292
- Checking the Crankcase
  292
- Disassembling the Crankcase
  292
- Installing the Oil Pressure Switch
  294
- Checking the Cylinder and Piston
  297
- Connecting Rods and Pistons
  297
- Removing the Connecting Rods and Pistons
  297
- Checking the Piston Pin
  298
- Checking the Piston Rings
  298
- Checking the Connecting Rods
  299
- Installing the Connecting Rod and Piston
  302
- Crankshaft and Balancer Shaft
  305
- Checking the Balancer Shaft Assembly
  306
- Removing the Balancer Shaft Journal Bearings
  306
- Removing the Crankshaft Journal Bearings
  306
- Checking the Crankshaft
  308
- Installing the Balancer Shaft Assembly
  310
- Installing the Crankshaft
  310
- Transmission
  311
- Checking the Shift Drum Assembly
  315
- Checking the Shift Forks
  315
- Removing the Transmission
  315
- Assembling the Main Axle and Drive Axle
  316
- Checking the Transmission
  316
- Installing the Transmission
  317
Cooling System

319
- Cooling System Diagrams
  320
- Radiator
  321
- Checking the Radiator
  323
- Installing the Radiator
  323
- Oil Cooler
  324
- Checking the Oil Cooler
  326
- Checking the Water Jacket Joint
  326
- Installing the Oil Cooler
  326
- Thermostat
  327
- Checking the Thermostat
  328
- Installing the Thermostat
  328
- Water Pump
  329
- Assembling the Water Pump
  332
- Checking the Water Pump
  332
- Disassembling the Water Pump
  332
- Installing the Clutch Cover
  334
Fuel System

335
- Fuel Tank
  336
- Removing the Fuel Pump
  340
- Removing the Fuel Tank (Left)
  340
- Removing the Fuel Tank (Right)
  340
- Removing the Fuel Tank Side Covers
  340
- Checking the Fuel Pump Body
  341
- Checking the Purge Cut Valve Solenoid
  341
- Installing the Canister
  341
- Installing the Fuel Pump
  341
- Installing the Fuel Tank (Left)
  341
- Installing the Fuel Tank Side Covers
  341
- Installing the Fuel Tank Center Cover
  342
- Throttle Bodies
  343
- Checking and Cleaning the Throttle Bodies
  346
- Checking the Injectors
  346
- Checking the Injectors (before Removing)
  346
- Removing the Injectors
  346
- Removing the Throttle Bodies
  346
- Adjusting the Throttle Position Sensor
  349
- Checking the Throttle Body Joints
  349
- Replacing the Throttle Bodies
  349
- Checking the Injector Pressure
  350
- Installing the Fuel Injectors
  350
- Checking the Fuel Pressure
  351
- Installing the Throttle Body Joints
  351
- Installing the Air Filter Case Joints
  352
- Installing the Throttle Bodies
  352
Electrical System

353
- Circuit Diagram
  356
- Ignition System
  356
- Engine Stopping Due to Sidestand Operation
  358
- Troubleshooting
  359
- Circuit Diagram
  362
- Electric Starting System
  362
- Starting Circuit Cut-Off System Operation
  364
- Troubleshooting
  365
- Charging System
  367
- Circuit Diagram
  367
- Troubleshooting
  368
- Circuit Diagram
  370
- Lighting System
  370
- Troubleshooting
  372
- Circuit Diagram
  374
- Signaling System
  374
- Troubleshooting
  376
- Circuit Diagram
  382
- Cooling System
  382
- Troubleshooting
  384
- Circuit Diagram
  386
- Fuel Pump System
  386
- Troubleshooting
  388
- Electrical Components
  390
- Checking the Switches
  392
- Checking and Charging the Battery
  393
- Checking the Fuses
  393
- REPLACING the ECU (Engine Control Unit)
  393
- Checking the Relays
  394
- Checking the Diode
  395
- Checking the Relay Unit (Diode)
  396
- Checking the Ignition Coils
  397
- Checking the Ignition Spark Gap
  397
- Checking the Crankshaft Position Sensor
  398
- Checking the Lean Angle Sensor
  398
- Checking the Rectifier/Regulator
  399
- Checking the Starter Motor Operation
  399
- Checking the Stator Coil
  399
- Checking the Coolant Temperature Sensor
  400
- Checking the Fuel Meter
  400
- Checking the Fuel Sender
  400
- Checking the Radiator Fan Motor
  400
- Checking the Throttle Position Sensor
  401
- Checking the Intake Air Pressure Sensor
  402
- Checking the Intake Air Temperature Sensor
  402
- Checking the Gear Position Switch
  403
- Checking the Fuel Cut Solenoid Valve
  404
- Checking the Fuel Injectors
  404
- Checking the Purge Cut Valve Solenoid
  404
Self Diagnostic

407
- Checking the Warning Light
  414
- Glossary
  414
- Outline
  414
- Ydt
  415
- Cope with the Mil Flashing
  416
- Parts Connected to the Abs Ecu
  416
- Parts Connected to the Ecu
  416
- Precautions for Road Test
  416
- Ecu Circuit Diagram
  418
- System Diagram
  418
- Ecu Coupler Layout
  420
- Circuit Diagram
  422
- Fuel Injection System
  422
- Basic Process for Troubleshooting
  424
- [A] the Mil Comes On/Flashes and Engine Operation Is Not Normal
  425
- [B] the Mil Does Not Come On, but the Engine Operation Is Not Normal
  425
- Circuit Diagram
  426
- Immobilizer System
  426
- Part Replacement and Key Code Registration Requirements
  428
- System Outline
  428
- Troubleshooting
  432
- How to Check Dtc
  433
- Circuit Diagram
  434
- Abs Troubleshooting Outline
  437
- Maintenance of the Abs Ecu
  437
- Basic Instructions for Troubleshooting
  438
- [A-1] Only the Abs Warning Light Fails to Come on
  440
- [A-2] All Indicator Lights Fail to Come on
  440
- [A-3] the Abs Warning Light Comes on
  440
- [A-4] Only the Abs Ecu Fails to Communicate
  440
- [A] Checking the Abs Warning Light
  440
- [A-5] Abs Ecu and Fi Ecu Fail to Communicate
  441
- [B-1] Malfunction Are Currently Detected
  441
- [B-2] Diagnosis Using the Dtc
  441
- [B-3] Deleting the Dtc
  442
- [C-1] Final Check
  442
- Dtc Table
  443
- Self-Diagnostic Function and Diagnostic Code Table
  443
- Self-Diagnostic Function Table (for Fuel Injection System)
  446
- SELF-DIAGNOSTIC FUNCTION TABLE (for ABS (Anti-Lock Brake System))
  456
- Self-Diagnostic Function Table (for Immobilizer System)
  456
- Communication Error with the Meter
  461
- Diagnostic Code: Sensor Operation Table
  462
- Diagnostic Code: Actuator Operation Table
  464
- Event Code Table
  466
- 30_Event
  469
- Troubleshooting
  469
- 70_Event
  471
- Troubleshooting
  471
- Troubleshooting
  472
- P0030
  473
- Troubleshooting
  473
- P00D1, P2195
  477
- Troubleshooting
  477
- P0105
  481
- Troubleshooting
  481
- P0106
  483
- Troubleshooting
  483
- P0107, P0108
  485
- Troubleshooting
  485
- P0110
  489
- Troubleshooting
  489
- P0111
  491
- Troubleshooting
  491
- P0112, P0113
  494
- Troubleshooting
  494
- P0115
  498
- Troubleshooting
  498
- P0116
  499
- Troubleshooting
  499
- P0117, P0118
  502
- Troubleshooting
  502
- P0122, P0123
  506
- Troubleshooting
  506
- P0132
  510
- Troubleshooting
  510
- Fail-Safe System
  513
- Outline
  513
- P0133
  513
- Troubleshooting
  514
- P0134
  515
- Troubleshooting
  515
- P0201
  517
- Troubleshooting
  517
- P0202
  521
- Troubleshooting
  521
- Outline
  525
- Fail-Safe System
  526
- Troubleshooting
  526
- P0335
  529
- Troubleshooting
  529
- P0351
  532
- Troubleshooting
  532
- P0352
  536
- Troubleshooting
  536
- P0458
  540
- Troubleshooting
  540
- P0480
  544
- Troubleshooting
  544
- P0507
  547
- Troubleshooting
  547
- P0511
  553
- Troubleshooting
  553
- P0560, P0563
  557
- Troubleshooting
  557
- P0601
  558
- Troubleshooting
  558
- P062F
  559
- Troubleshooting
  559
- P0657
  561
- Troubleshooting
  561
- P1500
  565
- Troubleshooting
  565
- P1601
  576
- Troubleshooting
  576
- P1602
  580
- Troubleshooting
  580
- P1604, P1605
  584
- Troubleshooting
  584
- Troubleshooting
  587
- U0155 or Err
  587
- 51_Immobilizer
  590
- Troubleshooting
  590
- 52_Immobilizer
  591
- Troubleshooting
  591
- 53_Immobilizer
  592
- Troubleshooting
  592
- 54_Immobilizer
  593
- Troubleshooting
  593
- 55_Immobilizer
  594
- Troubleshooting
  594
- 56_Immobilizer
  595
- Troubleshooting
  595
- 11, 25_Abs
  596
- Troubleshooting
  596
- 12_Abs
  597
- Troubleshooting
  597
- 13, 26_Abs
  598
- Troubleshooting
  598
- 14, 27_Abs
  599
- Troubleshooting
  599
- 15_Abs
  600
- Troubleshooting
  600
- 16_Abs
  602
- Troubleshooting
  602
- 17, 45_Abs
  604
- Troubleshooting
  604
- 18, 46_Abs
  605
- Troubleshooting
  605
- 21_Abs
  606
- Troubleshooting
  606
- 24_Abs
  607
- Troubleshooting
  607
- 31_Abs
  609
- Troubleshooting
  609
- 32_Abs
  611
- Troubleshooting
  611
- 33_Abs
  612
- Troubleshooting
  612
- 34_Abs
  614
- Troubleshooting
  614
- 41_Abs
  615
- Troubleshooting
  615
- 42, 47_Abs
  616
- Troubleshooting
  616
- 43_Abs
  617
- Troubleshooting
  617
- 44_Abs
  618
- Troubleshooting
  618
- 51, 52_Abs
  619
- Troubleshooting
  619
- 53_Abs
  620
- Troubleshooting
  620
- 54_Abs
  622
- Troubleshooting
  622
- 56_Abs
  624
- Troubleshooting
  624
- 63_Abs
  625
- Troubleshooting
  625
- 64_Abs
  627
- Troubleshooting
  627
- 89_Abs
  629
- Troubleshooting
  629
- 90_Abs
  631
- Troubleshooting
  631

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Yamaha XTZ690DP Owner's Manual

Yamaha XTZ690DP Owner's Manual (114 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10 MB

Table of Contents

Table of Contents
1
Location of Important Labels
8
Safety Information
10
Description
15
Left View
15
Right View
16
Controls and Instruments
17
Main Display Screen
18
Special Features
20
Ccu
20
(Communication Control Unit)
20
Instrument and Control Functions
22
Immobilizer System
22
Main Switch/Steering Lock
23
Handlebar Switches
24
Indicator Lights and Warning Lights
26
Display Main Screen
28
Menu System
34
Clutch Lever
39
Shift Pedal
39
Brake Lever
40
Brake Pedal
40
Abs
40
Fuel Tank Caps
41
Fuel
42
Fuel Tank Overflow Hose
43
Catalytic Converter
44
Seats
44
Adjusting the Headlight Beams
45
Adjusting the Front Fork
46
Front Fork Bleeding
48
Adjusting the Shock Absorber Assembly
49
Adjusting the Steering Damper
51
Luggage Strap Holders
52
Front Fender
52
DC Power Outlets
52
Sidestand
53
Ignition Circuit Cut-Off System
54
For Your Safety - Pre-Operation Checks
56
Operation and Important Riding Points
59
Engine Break-In
59
Starting the Engine
60
Shifting
61
Tips for Reducing Fuel Consumption
62
Parking
62
Periodic Maintenance and Adjustment
63
Tool Kit
64
Periodic Maintenance Charts
65
Periodic Maintenance Chart for the Emission Control System
65
General Maintenance and Lubrication Chart
67
Checking the Spark Plugs
71
Canister
72
Engine Oil and Oil Filter Cartridge
72
Why Yamalube
76
Coolant
76
Replacing the Air Filter Element and Cleaning the Check Hose
78
Checking the Engine Idling Speed
79
Checking the Throttle Grip Free Play
79
Valve Clearance
80
Tires
80
Spoke Wheels
82
Adjusting the Clutch Lever Free Play
82
Checking the Brake Lever Free Play
83
Brake Light Switches
83
Checking the Front and Rear Brake Pads
84
Checking the Brake Fluid Level
84
Changing the Brake Fluid
86
Drive Chain Slack
86
Cleaning and Lubricating the Drive Chain
88
Checking and Lubricating the Cables
88
Checking and Lubricating the Throttle Grip and Cable
89
Checking and Lubricating the Brake and Shift Pedals
89
Checking and Lubricating the Brake and Clutch Levers
90
Checking and Lubricating the Sidestand
90
Lubricating the Rear Suspension
91
Lubricating the Swingarm Pivots
91
Checking the Front Fork
91
Checking the Steering
92
Checking the Wheel Bearings
92
Battery
93
Replacing the Fuses
94
Vehicle Lights
95
License Plate Light
96
Supporting the Motorcycle
96
Troubleshooting
97
Troubleshooting Chart
98
Motorcycle Care and Storage
100
Matte Color Caution
100
Care
100
Storage
103
Specifications
105
Consumer Information
107
Identification Numbers
107
Diagnostic Connector
108
Vehicle Data Recording
108
Motorcycle Noise Regulation (for Australia)
109
Index
110

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