Yamaha XSR MTM690 2016 User manual

2016

SERVICE MANUAL

MTM690

MTM690-U

B34-F8197-E0

EAS20002

MTM690/MTM690-U

SERVICE MANUAL

First edition, November 2015

Any reproduction or unauthorized use

without the written permission of

MBK Industrie

is expressly prohibited.

EAS20003

IMPORTANT

This manual was produced by MBK Industrie. primarily for use by Yamaha dealers and their qualified

mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-

one who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic

understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-

nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit

for use.

Yamaha Motor Company, Ltd. and MBK Industrie are continually striving to improve all of its models.

Modifications and significant changes in specifications or procedures will be forwarded to all authorized

Yamaha dealers and will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

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 inju-

ry hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation

and assembly procedure, reverse the steps.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool Wheel bearing grease

Tightening torque Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil Replace the part with a new one.

Silicone fluid

New

EAS10003 TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND

ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

COOLING SYSTEM 6

FUEL SYSTEM 7

ELECTRICAL SYSTEM 8

TROUBLESHOOTING 9

GENERAL INFORMATION

IDENTIFICATION ............................................................................................1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

MULTI-FUNCTION METER UNIT .............................................................1-2

IMPORTANT INFORMATION .........................................................................1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS ....................................................1-7

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-7

BEARINGS AND OIL SEALS ....................................................................1-8

CIRCLIPS ..................................................................................................1-8

RUBBER PARTS.......................................................................................1-8

BASIC SERVICE INFORMATION...................................................................1-9

QUICK FASTENERS.................................................................................1-9

ELECTRICAL SYSTEM...........................................................................1-10

SPECIAL TOOLS ..........................................................................................1-14

IDENTIFICATION

1-1

EAS20007

IDENTIFICATION

EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

EAS30003

MODEL LABEL

The model label “1” is affixed to the frame under

the seat. This information will be needed to order

spare parts.

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