2016 YAMAHA XSR 700 suspension

Table of contentsSafety information............................ 1-1
Description....................................... 2-1
Left view ......................................... 2-1
Right view ....................................... 2-2
Controls and instruments ............... 2-3
Instrument and control functions... 3-1
Immobilizer system......................... 3-1
Main switch/steering lock............... 3-2
Indicator lights and warning
lights............................................ 3-4
Multi-function meter unit ................ 3-6
Handlebar switches ...................... 3-12
Clutch lever .................................. 3-13
Shift pedal .................................... 3-14
Brake lever.................................... 3-14
Brake pedal .................................. 3-14
ABS .............................................. 3-15
Fuel tank cap ................................ 3-16
Fuel ............................................... 3-16
Fuel tank breather hose and
overflow hose ............................ 3-18
Catalytic converter ....................... 3-18
Seat .............................................. 3-19
Helmet holding cable.................... 3-19
Adjusting the shock absorber
assembly ................................... 3-21
Sidestand ..................................... 3-22
Ignition circuit cut-off system ....... 3-22
Auxiliary DC connector ................. 3-24For your safety – pre-operation
checks............................................... 4-1
Operation and important riding
points................................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-4
Engine break-in ............................... 5-4
Parking ............................................ 5-5
Periodic maintenance and
adjustment........................................ 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and
lubrication chart ........................... 6-4
Checking the spark plugs ............... 6-8
Canister ........................................... 6-9
Engine oil and oil filter cartridge...... 6-9
Coolant.......................................... 6-12
Replacing the air filter element
and cleaning the check hose..... 6-15
Checking the throttle grip free
play ............................................ 6-15
Valve clearance ............................. 6-16
Tires .............................................. 6-16
Cast wheels................................... 6-18Adjusting the clutch lever free
play ............................................ 6-19
Checking the brake lever free
play ............................................ 6-19
Brake light switches ..................... 6-20
Checking the front and rear brake
pads .......................................... 6-20
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-22
Drive chain slack........................... 6-23
Cleaning and lubricating the drive
chain.......................................... 6-24
Checking and lubricating the
cables ........................................ 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and shift pedals............... 6-26
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
sidestand................................... 6-27
Lubricating the rear suspension ... 6-27
Lubricating the swingarm
pivots......................................... 6-28
Checking the front fork ................. 6-28
Checking the steering................... 6-29
Checking the wheel bearings ....... 6-29
Battery .......................................... 6-29
Replacing the fuses ...................... 6-31
Replacing the headlight bulb ........ 6-33UB34E0E0.book Page 1 Friday, July 10, 2015 10:31 AM

Safety information
1-3
1Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
Maximum load:
172 kg (379 lb)
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Safety information
1-4
1 tents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension travel,steering travel or control opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
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Safety information
1-5
1operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
6-16 for tire specifications and more in-
formation on replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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Instrument and control functions
3-21
3
EAU47001
Adjusting the shock absorber
assemblyThis shock absorber assembly is
equipped with a spring preload adjust-
ing ring.NOTICE
ECA10102
To avoid damaging the mechanism,
do not attempt to turn beyond the
maximum or minimum settings.Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To
decrease the spring preload and there-
by soften the suspension, turn the ad-
justing ring in direction (b).
Align the appropriate notch in the
adjusting ring with the position in-
dicator on the shock absorber.
Use the special wrench and ex-
tension bar included in the own-
er’s tool kit to make the
adjustment.
WARNING
EWA10222
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber assembly.Do not tamper with or attempt
to open the cylinder assembly.
Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
Do not dispose of a damaged or
worn-out shock ab
sorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
1. Extension bar
2. Special wrench
3. Spring preload adjusting ring
4. Position indicatorSpring preload setting:
Minimum (soft):
1
Standard:
3
Maximum (hard):
9
7 6
9 8 5 4 3 2 1
3(a)(b)
2
1
4
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Periodic maintenance and adjustment
6-6
6
21*Front fork• Check operation and for oil leak-
age.√√√√
22*Shock absorber as-
sembly• Check operation and shock ab-
sorber for oil leakage.√√√√
23*Rear suspension re-
lay arm and con-
necting arm
pivoting points• Check operation.√√√√
• Lubricate with lithium-soap-
based grease.√√
24 Engine oil• Change.
• Check oil level and vehicle for oil
leakage.√√√√√√
25Engine oil filter car-
tridge•Replace.√√√
26*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
27*Front and rear
brake switches• Check operation.√√√√√√
28Moving parts and
cables• Lubricate.√√√√√
29*Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing.√√√√√
30*Lights, signals and
switches
• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
UB34E0E0.book Page 6 Friday, July 10, 2015 10:31 AM

Specifications
8-2
8
Chassis:Frame type:
Diamond
Caster angle:
25.0 °
Trail:
90 mm (3.5 in)Front tire:Type:
Tubeless
Size:
120/70 R17M/C (58V)
Manufacturer/model:
PIRELLI/PHANTOM SPORTSCOMPRear tire:Type:
Tubeless
Size:
180/55 R17M/C (73V)
Manufacturer/model:
PIRELLI/PHANTOM SPORTSCOMPLoading:Maximum load:
172 kg (379 lb)
(Total weight of rider, passenger, cargo
and accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–173 kg (0–381 lb)
Front:
225 kPa (2.25 kgf/cm², 33 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)High-speed riding:
Front:
225 kPa (2.25 kgf/cm², 33 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Front wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT3.50Rear wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT5.50Front brake:Type:
Dual disc brake
Operation:
Right hand operation
Specified brake fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Specified brake fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damperWheel travel:
130 mm (5.1 in)
Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
130 mm (5.1 in)Electrical system:System voltage:
12 V
Ignition system:
TCI
Charging system:
AC magnetoBattery:Model:
YTZ10S
Voltage, capacity:
12 V, 8.6 AhHeadlight:Bulb type:
Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 60.0 W/55.0 W × 1
Brake/tail light:
LED
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 10.0 W × 2
UB34E0E0.book Page 2 Friday, July 10, 2015 10:31 AM

10-1
10
Index
AABS....................................................... 3-15
ABS warning light ................................... 3-5
Air filter element and check hose,
replacing and cleaning ....................... 6-15
Auxiliary DC connector ......................... 3-24
Auxiliary light bulb, replacing ............... 6-35BBattery .................................................. 6-29
Brake and clutch levers, checking and
lubricating........................................... 6-26
Brake and shift pedals, checking and
lubricating........................................... 6-26
Brake fluid, changing............................ 6-22
Brake fluid level, checking.................... 6-21
Brake lever............................................ 3-14
Brake lever free play, checking ............ 6-19
Brake light switches ............................. 6-20
Brake pedal .......................................... 3-14CCables, checking and lubricating ......... 6-25
Canister .................................................. 6-9
Care ........................................................ 7-1
Catalytic converter ............................... 3-18
Clutch lever........................................... 3-13
Clutch lever free play, adjusting ........... 6-19
Coolant ................................................. 6-12
Coolant temperature warning light ......... 3-4DDiagnostic connector ............................. 9-2
Dimmer switch...................................... 3-13
Drive chain, cleaning and lubricating ... 6-24
Drive chain slack .................................. 6-23
EEngine break-in ...................................... 5-4
Engine oil and oil filter cartridge............. 6-9
Engine serial number ............................. 9-1
Engine trouble warning light .................. 3-5FFront and rear brake pads, checking ... 6-20
Front fork, checking ............................. 6-28
Fuel ...................................................... 3-16
Fuel consumption, tips for reducing ...... 5-4
Fuel tank breather hose and overflow
hose ................................................... 3-18
Fuel tank cap........................................ 3-16
Fuses, replacing ................................... 6-31HHandlebar switches ............................. 3-12
Hazard switch ...................................... 3-13
Headlight bulb, replacing ..................... 6-33
Helmet holding cable ........................... 3-19
High beam indicator light ....................... 3-4
Horn switch .......................................... 3-13IIdentification numbers ........................... 9-1
Ignition circuit cut-off system .............. 3-22
Immobilizer system ................................ 3-1
Immobilizer system indicator light ......... 3-6
Indicator lights and warning lights ......... 3-4LLicense plate light ................................ 6-36MMain switch/steering lock ...................... 3-2
Maintenance and lubrication, periodic... 6-4
Maintenance, emission control
system ................................................. 6-3Matte color, caution................................ 7-1
Model label ............................................. 9-1
Multi-function meter unit ........................ 3-6
NNeutral indicator light ............................. 3-4OOil pressure warning light ....................... 3-4PParking.................................................... 5-5
Part locations.......................................... 2-1
Pass switch........................................... 3-13RRear suspension, lubricating ................ 6-27SSafety information................................... 1-1
Seat....................................................... 3-19
Shifting.................................................... 5-2
Shift pedal............................................. 3-14
Shock absorber assembly, adjusting ... 3-21
Sidestand.............................................. 3-22
Sidestand, checking and lubricating .... 6-27
Spark plugs, checking ............................ 6-8
Specifications ......................................... 8-1
Starting the engine ................................. 5-1
Steering, checking ................................ 6-29
Stop/Run/Start switch .......................... 3-13
Storage ................................................... 7-3
Supporting the motorcycle ................... 6-37
Swingarm pivots, lubricating ................ 6-28TTail/brake light ...................................... 6-35
Throttle grip and cable, checking and
lubricating ........................................... 6-25
Throttle grip free play, checking ........... 6-15
UB34E0E0.book Page 1 Friday, July 10, 2015 10:31 AM